OK, bumped this one because I finally got around to dismantling my door yesterday (I lead a busy life, windows are not a high priority unless my AC fails
)
Anyway, that's not the problem. The cables are perfectly spooled and aligned, but it looks like the center "drive" part of the pulley is slipping around inside said pulley making a "click" sound.
What do you think? Stripped out pulley? I did it late last night, so just unbolted the motor from the door to check it out, I did not remove it from the car. Would it be easy enough to get a replacement pulley, or just replace the whole assembly?