So the bottom of my passenger side sliding door is rusting out. A replacement door from the salvage yard is $125, so how hard is it to remove the old door and install the new one?​
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The hard part was locating a suitable replacement door. Preferably in the same color, and little or no damage. Finally I found one! (Transmission might be bad, but the door is great!)
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The rusted condition of my old door
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Donor door in much better condition
Taking it off was fairly simple and straightforward!
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Notice alignment marks on cover plate and bracket
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Cover plate with roller
Be sure to switch off the power door on the left side of the dashboard before proceeding. (This was not necessary at the junk yard!) The bottom bracket has a 12mm nut holding a cover plate - remove only the front nut! The plate has a roller and locks the bottom bracket to the track. Remove the nut and plate, you might have to slide the door forward (close) a bit.

​Next, ​use a 12mm socket to remove the two bolts that attach the door to the center roller. (The trim piece does not need to be removed as in my picture.) You do need to hold the door as the last bolt is removed. Now you can lift up and pull the bottom out, working the lower bracket off and out of the lower track. Do this by moving the door further to the back, and now the roller can pull out of the track. With the bottom bracket free, the bottom of the door can be angled away from the body allowing the top roller to come out of it's track. Removing the door I was able to do this by myself. Having an assistant help is not required but highly recommended!
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With the rear seat stowed and center seats moved forward, there was plenty of room for my 'new' door laid flat in the back of the van. When I picked up a second door for my nephew's 2002 Odyssey, I stood the door on its rear side, and slid it on a clean carpet in between the middle row seats.

Reinstalling the door

​Manually closing the door, make sure the rollers were properly installed. My alignment was fairly good.
​With installation, my nephew helped me. After opening the power door, switched off the power. Remove the rusted door just like above.

To install, first we angled the upper roller into the track in the top rail. My nephew held the back end of the door, and I worked the upper and then bottom roller into their tracks. When the bottom roller is in place, the front of the door can be released. Now the back of the door can be bolted back onto the center track roller assembly. Snug, but don't tighten those bolts yet.

The bottom roller rides on a metal plate. It's easy to push the door all the way in, and the roller ends up past the plate. You can see the plate in the picture below with the grease and track from the roller. Pull the door up slightly and move it so the roller rests on the plate. Then install the cover plate and secure it to the bottom bracket with the nut.
To reset the power door mechanism, open the door fully. Switch the door power back on, then push and hold the Close button until the door is fully closed. The power mechanism worked great! With the door closed, check the alignment. The front was perfect! The back was a bit too high. So with the door opened, the two center bolts can be loosened and the door moved the appropriate direction. Snug the bolts and check the alignment when closed. Once the alignment is good, tighten those two bolts!
​If the front alignment needs to be adjusted up or down, there are two bolts at the bottom edge of the door that secure the bracket. There is also a third bolt hidden behind a round plug. With the three bolts loosened, the front bottom corner can be moved up or down. Probably want to switch off the power door, and open the door partially in order to loosen the bolts. Adjust and tighten.

This was so easy, I ended up replacing the sliding door two more- no, 4 times! My nephew's 2002 Ody is now mine. The door I picked up from the junk yard and installed was just a shade darker. When I got the 2002 I swapped the doors with my old '99 before I junked it. Now the match was perfect for me!