I have a 01 Td5 since August and before giving it to me the previous owner fitted a new regulator to the drivers window.
Yesterday evening as I raised the window there was a bang and the sound of something falling inside the door - and of course the glass headed down. Jammed the glass up and when I got home put two pieces of wood under the glass and discovered the semicircular piece with the teeth on it had come off the arm - the spot welds had failed .
The regulator is almost as new and I was wondering would it be worthwhile having it repaired - could it be welded with a mig for example ( or what kind of material is in the regulator ?)
I have seen this happen on Tdi's a few times but the regulators had been in use for a few years so repair wasn't considered due to their age .

Mine failed it was the nylon roller giving up the thing went bang, as u say, I went out and got a new regulator but now realise I could have found something to use as a replacement roller then straighten up the metal which was bent and reused it regulator and saving my self £75..

So if you can get the welds redone do so or even use a couple of small nut and bolts may work where weld has broken if there is clearance.

Mine did this whilst on holiday in Ireland this year. I found myself a local welder, we drilled out the old welds, put some thick welding rod in and welded it all back up. It now works as intended and saved me god knows how much money.

I wonder if you couldn't switch out the plastic for rollers like Saabs have. They don't last forever but you can buy just the roller part.???

My window regulator fail, I first welded which was unsucessful - seemed like the weld material and the parent metal was incompatible. Used small csk hd screws and nuts is i remember rightly. Never any more problems.
Disco '96

RED

regulator went on my 96 disco, i drilled through the spots where it was welded and used a rivet gun to secure back in place, managed to do this without removing the unit from the door, just unbolted the unit to give me access to the weld spots, a little tricky keeping the holes aligned and resecuring the unit, but worked a treat and only took an hour to do. It provides a stronger fixing than the original spot welds so shouldnt have that problem ever again.