I have just had the same problem in my front passenger door. A parts man said it is the roller making a cracking noise and if the window keeps getting used it destroys the mechanism.
Haven't fixed mine yet, but it means making new nylon rollers, or buying them for $40 rather than $200 for a new actuator.
Contact me off-line and I will give you the address,
cheers Chazza


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Thanks Wayne. I felt sure I had seen it on here. Good article of yours.

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