This is just a heads up if you work on the new Chrysler mini van front doors. I recently worked on a 08 Chrysler mini van right front door. It was a real easy basic door ding. Maybe close to a foot down from the top of the door , below the glass.midway from front to rear. For some reason they put a block of styrofoam in the door , that rest on a cross beam and is held on by a small piece(about the size of a postage stamp) of two sided tape at the top of this styrofoam block that holds it to the inside of the door skin. I rolled the window down and started working my tool around and bumped the styrofoam maybe a couple of times.(I didnt know it was even there at first). But it knocked the foam block loose and it fell to the bottom of the door. When it fell, I heard something , but I didnt know what it was. When I was done with fixing the ding . The window went back up just fine. So I never gave it a second thought.
Well I got called back out to the residence. They said their window doesnt go all the way back down now !! Huh !?? I thought. Thats odd, I never used much force in fixing the ding.Not enough to bend any window bracket or linkage. The door panel is held on by push in type retainers.Take the two screws out, one by the door handle you use to grab and close the door and one by the door release lever.The push in retainers are a bit tough to get started taking the door panel off. I took my cake knife / glue cutter and slide that in at the bottom of the door panel between the panel and the metal door body.Twist the cake cutter just alittle to give your self a small gap to get your plastic wedge in and start poping the retainers loose. Once you have the door panel off. They have redesigned the inside of the door. All the mechanics of the door are bolted to a large removeable panel. The panel is some kind of composit material.My first thought was , Damn , now I have to take all this off to get to the stryrofoam block that fell. There are no openings already there to access through. Dont pull all this off. Its not nesesary. Just pull the speaker out and pull it out through the hole there. Its alittle tight, but it will come out……………..What had happened, when the block fell to the bottom of the door and laid there. The window would only come down as far as it could then it hit the styrofoam block that was laying there. And it couldnt go any futher. I pulled the foam block out and left it out……………..If you work on these Chrysler mini van doors, its going to happen to you.!!! This is just a heads up to let you know….. Chip