My drivers side door makes an awful cracking popping sound when opening and closing. I can hear that the guide plate / roller is where the noise is coming from. I can also see that the roller is not rolling freely and the roller itself has couple divots / wear marks at the point where the roller doesn't want to roll any further. FYI.. The pins and bushings are fine.. and thats not the issue. Has anyone had this problem? solution? :frown:

Oil it up.

My drivers side door makes an awful cracking popping sound when opening and closing. I can hear that the guide plate / roller is where the noise is coming from. I can also see that the roller is not rolling freely and the roller itself has couple divots / wear marks at the point where the roller doesn't want to roll any further. FYI.. The pins and bushings are fine.. and thats not the issue. Has anyone had this problem? solution? :frown:

As said lube it up good.

Usually caused by fast/jiffie lube places that do not take the time to lube door hinges and latches as the should.
Let us know how it goes.

yep.. have been oiling it up. I even took the spring off the door with my special spring tool. After I took the tension off it, it spun freely with no noise. but with pressure on it from the spring it pops as the door is opening / closing. I fear that if this goes unchecked it will wear the roller soo much that the door won't be able to open or close properly..(not that it does now). Worst case scenario I'll have to take the spring out and just use it that way. Or is there a surefire way to replace the roller?

yep.. have been oiling it up. I even took the spring off the door with my special spring tool. After I took the tension off it, it spun freely with no noise. but with pressure on it from the spring it pops as the door is opening / closing. I fear that if this goes unchecked it will wear the roller soo much that the door won't be able to open or close properly..(not that it does now). Worst case scenario I'll have to take the spring out and just use it that way. Or is there a surefire way to replace the roller?

Sound like you need to replace the roller and all it rools on.
Or maybe the hole hinge.
Check with your dealer parts department and see what they have for it.
Good luck