Re: Any alternative fixes for broken door check strap weld?
Because of the internal bracing in the door and the window channel, pictures of the back of the cup would be difficult. I tried to take some when I was doing the repair, but they didn't come out well.
Removing the door panel is easy. There are instructions one here somewhere, but basically, remove the mirror trim cover (just pops off), remove the arm rest pocket. There is a screw if I recall, that holds it on and a screw in the door pull. It slides towards the back of the door before you can lift it out. The front of the pocket has a tab that slips into the door panel. Once it is free, you can unplug the harness going to the window controls. There is a large screw in the center of the panel under the door pull and a plastic "screw" on the panel at the back edge of the door panel. It is actually a fastener that has a plastic screw center. The door panel itself is held in place by a number of panel clips that press into holes in the door. A panel puller works best to remove these to insure the least likelyhood of breaking one, but it can be done with a screwdriver (as wide of a blade as possible). Once you have all of the panel clips loose, the door panel needs to be lifted straight up towards the top of the van to remove it from the window track. Once you have it completely loose, you have to reach around and release the two door lock/latch cables and the panel should be free. You will also need to remove the speaker to get good access to the front of the door where the cup is. The speaker just has 4 screws holding it in.
I've done it so many times between replacing speakers, doing sound deadening and repairing the door check, it took longer to write out this description than it does for me to remove the panel now. It doesn't take much pressure at any point, so if something isn't budging, stop and see what you may have missed.