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As far as removing the un-broken roller: If you can't get the pin out and it won't pry off with a screwdriver... you can always use your pliers to break it! After all, you have a replacement.
The rollers are cheap... you might as well buy four when starting this job, because at some point they will fail again on one of the other windows. Might as well keep them on hand.
When mine failed, in the middle of winter, I was able to jerry-rig a temporary solution as follows:
1. Cut a piece of nylon plastic from an unused fishing-tackle-box divider to fit the height of the window channel. If necessary, cut two pieces to build up enough thickness that the plastic will slide in the channel but not fall out.
2. Drill a hole through the plastic part(s), insert a short machine screw, and bolt in place with nut(s)
3. Slide the closed end of a J-shaped picture-hanging hook over the end of the screw, and secure with another nut
4. Insert widget into window track.
5. Using heavy nylon zip-tie, attach hook to cotter pin that is securing remnants of the green roller to the window regulator.
This will work well enough to keep the window up for a few days while you secure the needed parts, and it will even let you put the window up and down *carefully* if you forget for a moment that your window is broken. :)
But by NO means would I suggest this as a permanent fix.
As for undoing the weatherproofing glue seal: I recommend a very sharp and clean utility knife. Cut the glue, NOT the foam door liner. The glue readily re-seals to itself after being cut. It does not re-seal to the metal door nearly as well.
One other tip: having an assistant to hold the window glass from "outside" of the door while you adjust the window lift to the right height for access to the rollers will make this job much less frustrating.
posted by 209.23.64...
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