had a same problem and fixed with adjustment of the width position of bottom roller and receiver for the latch/lock...was going to do the same thing you did (buying new rollers and ext) but it was simple adjustment... your top gap when you close slide door is because of the bottom roller needs to be opened up(there is 2 5 mm allen had screws) and once you adjust receiver position ..kind of push it out bit more,leave screws lightly loose and close the door ...then open it and tighten the screws,i got like 1 inch clearance between receiver and rubber for door ... everything will fall in smoothly...it did it good luck

I am experiencing a similar issue and just found that the plate that the mid slider attaches to the frame of the door came loose therefore causing a sag and not allowing the door to line up and close. Currently contemplating buying a new part or doing some MacGyver job to reattach that plate to the door frame somehow...

I think the three roller arms work in concert to hold the door solid in the relative position to the door frame (i.e. the three tracks). I suspect if you also replace the lower roller arm the play will be much less... I also think the up/down play is caused by a loose middle roller arm. Possibly the roller arm is the wrong type because it should hold the door quite snug in the track... I have understood the top roller arm holds the most of the weight of the door and prevents it from falling outward or inward, the middle roller holds also some of the weight (not sure what the distribution is thought, could very well be 50/50) and the lower roller arm only provides support in the inward/outward direction. If the weight is held by the top and middle roller arm the problem of the play should be in either or both of them... Either the wrong replacements parts were used or they were installed wrong My personal guess would be the middle roller, it has both a mounting bolt (the large one which you loosenend from the inside) and a locating tab which may be not engaged correctly making the roller arm either loose or orientated wrong to allow for some play. Looking at replacement roller arms it seems the door is not tensioned in place. I mean the weight of the door is held by the rollers in tracks which do not allow the rollers to get lifted out of the tracks but do allow for some play, possibly even some 5-7 mm up/down. The problem you seem to be having is the alignment of the door catch(es) which can and most likely need to be adjusted to have the door close properly...

Hey guys, just sitting in may vam trying to adjust all the new rollers and guides. It closed way better before i replaced the worn out stuff. Amyone know the magic trick yet?

I have the same issue right now! 2003 t1n sprinter. so much fine-tuning 18 bolts for everything to match, yay!

I am having the same problem with my 2005 Dodge Sprinter 2500. How frustrating! I have made adjustments that worked for a little while, and just replaced the upper and lower rollers today, but with little avail, the damn door still won’t close properly.

You can adjust top and bottom rollers the middle one you only adjust the strike plate

The mid slider is different for the 4ton vans gives more clearance for wheel arch’s

Hey Ronny, Ever get this sorted? -Hunter

Same problem. Frustrating as hell. Wish there was an option to replace whole door with barn style like American GM van.

I'm having the same issue. Have you found resolution?

I have the same issue. I can slide the door fine, and the door seems to be lined up, but the latch doesn't seem to hold. Unless I slam it shut or put a lot of pressure on the outer left side as I shut it. Did you ever find a solution?

you should study your van more