Here is another approach that worked great for me. I recently sold my 2000 'S' and the gentleman accidentally put to much stress on the window (I didn't show him well enough how the doors open with the top up) and either the cable stretched or a piece broke. Well anyway he came over before leaving for Kentucky and we came up with the great fix.
Using a bicycle cable barrel (yellow arrow) in the exact shape as the factory barrel (orange arrow), only smaller, we were able to pull up the 1/4 inch slack preventing the window from dropping far enough to open the door. It is kind of like stacking barrels.
To do this we had to file down the area the factory barrel recesses into (see green arrow). This allowed us to snap the barrel back into place since it was not possible to pull the cable enough to get the barrel back into the hole it seats in.
This fix would go very fast but while learning we dropped the cable off the pulley (red arrow). The cable is hard to get back on. There is a little notch in the pulley for getting it past the guide. Once back in though we were able to put the fix together.
I'd like to thank everyone that posted here, this forum still rocks. Saved us big time.
