I noticed the arm that rides down in the side of the door frame was binding when I went to put the new glass in today. It was a small oval notch I assume came over the years of vibration and when the door was closed it caused the arm to flex up and bend putting a strong load on the bottom of the glass along with a twist tweaking the entire assembly towards the outside of the door. Well I put this theory to the test using a thick glove and Ace bandage over my arm at the junkyard. After cranking the window of the donor car up with a battery I closed the door with about the same force as I used on my car and sure enough the glass EXPLODED! Looked at the nylon insert and it also had the same oval shape to it and was holding the arm back until the shock of the door closing unloaded everything and made the arm jump to a new home at the end.
In short replace that nylon bushing and until then only run the windows up just enough to seal them and dont stand on the button. That motor makes a hell of a lot of torque!

Total cost of the glass and experiment was $10.00 and a lession learned!

I cut the stitches out next friday