Hi, I have stripped and reassembled the drivers and passengers door four times now one of the times only this weekend gone, many thanks to IanG who supplied the necessary part(s)! The puma has a very particular way the windows are mounted and the doors are assembled.
The doors as a unit are made of three pieces:
The Door body (where all the electrics are and where the glass retracts into)
The Rubber/metal bar/frame
The Glass
The two issues with the glass not going up and down as it should are that the rubber frame isn't set straight and requires jiggling about to get the best fit, and the clamp (a green bracket that slides on a rail inside the door that allows adjustment via two bolts that clamp to another bracket attached to the glass itself) isn't as centred on the glass as it could be i.e. its pushing the front or back of the glass and making it turn as it rises.
What you need to do is:
1. Wind the window down all the way down.
2. Remove the door card (make sure you have replacement door card clips as they're "single use")
3. Locate the 4 bolts and 1 nut that fixes the frame to the door body. Two bolts on the trailing edge of the door, they're under a black plastic cover, gold coloured, have massive washers on and incredibly hard to miss. Two bolts on the leading edge of the door, one under the rubber flap near the wing mirror (just pull from underneath) and another under a black plastic cover. The nut is just above where the glass disappears into the door near the wing mirror end.
4. Loosen all four bolts and nut (do not remove) and rejiggle to straighten the frame up, you can adjust the door/frame angle and the nose/tail rotation by 'panning' the bolts about in their holes. tighten the nut at the top up but not the others, shut the door and make sure it seals all the way round the rubber lip, repeat if necessary. If you can pull the frame away from the car, then try again.
5. Once you have a good seal, open the door and tighten all the bolts up again.
6. Wind the window up and down a couple of times, see if you can find where the window starts to come out of alignment.
7. Locate the green carriage at the bottom inside the door, loosen the two screws inside it so they can be turned easily but not fall out. Drop the window slightly and tighten the screws back up again (if you can see them, if not, wind the window up whilst applying pressure to the glass so it runs straight up the vertical part of the frame, tighten screws through the Ford approved screw tightening holes)
8. Repeat 6-7 until happy
9. Wind window up and down a few times to check it doesnt jam again.
10. Repeat 6-9 until happy
11. Wind window up and down with door closed as well, just to make sure
12. Repeat 6-9 until happy
13. Replace switch gear, trim clips and door cards
13. Complete.
I've done this method each time the doors have been in pieces and has worked for me, i haven't had to use lubricant yet, though the time may come
