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I can't even guess how many times I've had the rear window assemblies out of my hardtop, but I can now do it in about 10 minutes, including seat removal.
There's a screw at the end of the motor shaft that controls the "lash" or free-play. If this is too tight (as it seems to be in all new motors), then the armature can't begin to move before the gear engages. Loosen the nut and back the screw off about 1/2 to 1 turn. That often helps.
Another problem is often a slight bit of binding in the track at the ends. Slightly loosen the track bolts on the front of the housing and run the window up and down while observing how the track moves. If either end is out of alignment, the rollers will bind.
The second photo is of the relay setup I've installed in the trunk so that the motors get full power. The switches only activate the relay coils, so there is no load through the almost non-existent contacts in the switch. Headlight, dash lights and windows have all had relays installed. It's made a big difference.
Hope this helps
Terry
64HT
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