I replaced the driver side sliding door roller assembly yesterday.
After days of pouring over the different threads and reading the how-to's, I figured out that it isn't really as hard as mentioned in the old threads.
No need to take any of the interior paneling off, no need to take the door off. Although I started out trying to do all this and wasted about 1.5hrs.
My steps to replace the sliding door roller assembly;
part #72561-SHJ-A21 Male Hinge $67.14 in Burnaby BC, Canada
Turn off power door switch!
Open door manually and support bottom with jack and soft cloth to protect paint. You may have to grab the hinge and keep it straight while opening the door so it won't bind.
Remove rear brake light housing with two bolts at rear and then slide housing to the rear to release male/female connector towards the front. (I used a piece of cereal box cardboard to protect the paint and hooked a paint can opener to the front edge of the light and pulled backward)
Remove the sliding door rail cover (body trim) by removing the 12mm bolt under the brake-light housing and the front screw visible in the open doorway when looking towards the rear of the vehicle. Slide the cover towards the rear to release the mounts.
**Important** Liberally apply masking tape to the auto paint surface in the area of the hinge. Top, double layer below hinge, inside door etc. You don't want to scratch your baby!
Mark the position of the bracket on the door with a felt tip pen. You'll want to mount it in the same spot later.
Remove the two 14mm bolts attached to the inside of the door and tilt the hinge upwards to release from track.
Now comes the fun part of getting just the right angle to release the rear cable. It hooks in like a bicycle brake cable. I used a pair of needle nose pliers. I also wrapped the wire with some masking tape and attached my vice grips to the cable. This allowed me to pull hard on the cable to get some slack. There should be just enough slack - no extra.
Once the back cable is off, it is easy to undo the front cable and remove the assembly.
Remove the pin from the hinge; Use a short socket (16mm or so) underneath the pin, remove the C-clamp washer and then whack it with a hammer. Put the new male hinge part on and replace pin and C-clamp washer noting the position of the spring as on old piece.
Attach the front and then rear wires. Attach bracket to door.
Re-attach body trim and tail light.
Close door manually
Go ask wife for reward.