Trimming the Window Clip to Prevent Window Scratching
This is my effort at a walk-through for fixing the window scratching problem experienced by many Saab 900's. It's caused by a clip that keeps the weatherstrip held tight against the window. The problem was that they're pointed sharply at it, and over time cut straight through the weatherstrip. This exposes the metal clip and causes it to scratch the window. In order to fix the problem I recommend a dremmel tool equipped with some kind of sander or grinder, as well as a set of Torx drivers for removing door panel parts and the glass (I don't remember exact sizes, but between 15 and 25 will work). Also, I STRONGLY SUGGEST going to the website linked below and ordering yourself a set of the weatherstripping. The stock ones are old and brittle and will crack apart. Ready? Here we go...
Window Scrapers
First we have to remove the door panel. To do this, remove the screws at the bottom of the door panel, one on the left, and one on the right. Then remove the door handle. There should be one torx screw holding that in. Also, don't forget to unscrew (by hand) the door lock tab thing (love the technical name).
Remove Felt Panel
Next, remove the felt panel. Lift out from the bottom and pull down, should slide out.
Next, remove the remaining visible torx screws that were just revealed by removing the felt panel. This should be enough to completely free the door panel from the door. There are two screws closer to the center, and two screws holding in clips. Those are all that need to be removed. You should then be able to lift up and remove the door panel.
You should reveal this, but with less DIY work on it (and duct tape) unless you've done this kind of thing before (or the previous owner did). Honestly, I have no idea what this stuff is for, but I'm gonna leave it alone, for the most part.
Unsecure Glass
Now's the fun part. Almost. We're going to remove the screws holding the glass in. The glass is attached to a metal strip that will come out WITH IT. That's okay. Our job is to remove the metal strip from the rising mechanism. To do this, we need to remove a few screws (Torx again). The X shape and lower bar is the rising mechanism. The bar resting on it is the bar we want to get loose.
And here I zoom in on the screws that need to be removed (2). This is what it looks like after you remove the two screws.
Remove the weatherstripping. It will come straight up if you pull hard. Don't worry, you won't break anything, but if you don't have the replacement weatherstripping then you might want to be careful because the stock ones WILL become damaged since they're so brittle. If you haven't already, go ahead and order those. Really. Go do that. Now.
See that? Already ruined. But it does come up pretty easily once you get it going. Now this reveals the clips, and you can see how pointy and sharp they are.
Now that the weatherstripping's gone, we can remove the window. Bring it up a bit so you can grasp it, and then slowly pull it up and out at an angle (rotating it slightly helps). Careful with the metal bar at the bottom. Hard to get out without paying attention. I don't have a picture of removing it because I removed it and everyone else was working on the Sub box for this car at the time:
This is the fun part. Actually grinding the clips. Don't worry, the sparks won't hurt anything. They're just there to make you feel cooler.
Be careful not to hit the sides, though doing so won't really cause that much damage.
Grind them down until they look like this:
And voila! You're done! Put everything back together in reverse order seen here, and you should be good! Just make sure that when you put the weatherstripping back that the inside flap (side on the window) actually goes OVER the clips all the way. Outside of that, job well done!