Someone could have done the front door before but I will be covering the rear door and will try to make it more comprehensive.

All the problems are caused by the 5 pieces of rubber parts that turned into pieces.

1. Remove door card.
2. Remove plastic sheet, partly, as shown below.
3. Remove the 2 circled screws as shown. Size = 10mm. Hold the stopper bracket at the back while unscrewing. Keep both brackets. You need to do something about them later.

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_141928_zpsec4d836a.jpg[/img]

4. Plug the window switch back and move the window glass up or down so that you can see the below 2 nuts + 1 screw. Remove them with a 10mm socket wrench.

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_142029_zps956f534c.jpg[/img]

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_142039_zpsaefebd66.jpg[/img]

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_142050_zps5be86982.jpg[/img]

5. Now, slide the glass upward. Be careful not to scratch your tint film (if any).

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_144204_zpsb96d27b3.jpg[/img]

6. Next 2 photos show the sliding rubber and roller turned themselves into sh!t-look-alike stuff.

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_144211_zpsee65f3dd.jpg[/img]

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_144233_zps0fa560af.jpg[/img]

7. Wrap the stopper brackets with rubber taken from an F-clamp and secure each of them with a cable tie.

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_144309_zps955f95bf.jpg[/img]

8. Now, remove 5x nuts (14 and 10mm) shown below.

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_1419282_zpsf17d4730.jpg[/img]

9. Disconnect power window motor and remove the whole power window assembly out of the door.

[img]http://i85.photobucket.com/albums/k73/cba6p/20131110_154746_zpsfed0e255.jpg[/img]

10. Roller disappeared!!!

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_154907_zpsad987c77.jpg[/img]

11. Grind off the head of the roller pin with a disc grinder and knock it out with a punch.

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_172254_zpsf91e30a0.jpg[/img]
[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_172247_zps14fcbae1.jpg[/img]
[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131110_174927_zps5828c70d.jpg[/img]

12. Drill Ø3.3 and tap an M4 x 10 deep hole at the centre of the pin. Get ready a button head M4 x 8 screw, a thin M4 washer and a new (reverse engineered) roller.

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131111_191718_zps38570e6f.jpg[/img]

13. Insert the pin into the roller and slot the assembly into the guide rail. Apply some Loctite 242 on the threaded hole.

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131116_183600_zps16d73657.jpg[/img]

14. Fasten the screw and it is how it looks like:

[img]http://i85.photobucket.com/albums/k73/cba6p/lantis/20131116_183822_zps83592d61.jpg[/img]

We are done with the power window assembly. Ready to put it back into the door.

TBC...

Hi,
does anybody know how / where to get new replacement bushes?
Cheers,
Chris

amazing tutorial dude... I have two windows ratlling, and with this, you help a lot know how to solve it... only left to know how get the buches (don't say Mazda cuse not worth the money they ask )

CSR

buches? XD

great work thank you

Nice write up. I will try your method since my windows are rattling a bit.

I still looking for those buches... only can fins for mx-5, witch seems to be the same issue. But only can find in US, and the price of postage is more than the set of 2 buches...

can someone know how to find a set in Europe?

I can halp u with that. I am currently importing a few sets. I'd need a down payment via Paypal until the weekend to include you. It should work out at about 80€ plus shipping from germany to portugal.
Feel free to DM me on insta if possible @lantisdoc

This is one of the most annoying and difficult things to fix in this car