Had to replace all the rollers on my 82.  I have treid several times to get the window adjusted using the shop manual and Aim instructions to no luck.  My problem is I cannot get enough outward adjustment.  The window rolls up to within about 1" of the top.  I am replacing the rear seal as it is hard and think this might be causing some of the issue.  If I roll it all the way up and shut the door, the motor will not roll it down.

Boy I wish I could help but I took mine to a friend who restores C3 and he did some trick things and unfortunately I did not pay much attention to what he was doing.  Now lining up the glass tops perfectly I did watch and can do that I believe if I ever have to again. 

Hopefully someone will see this in the next 24 and give you some hints.  If not you may want to take it to a body shop if you know one that you trust.  I have one because for about 10 years my wife got her car hit about every 18 months or so.  The guy knows me by sight and first name.  Knock on wood she has not been hit going on 5 years she did hit our front fence a year ago. 

Jeff, I have made some minor adjustments in my window glass before but I did not need a major correction like you describe.  If you are to the point of giving up and no one here comes to the rescue you may want to give Dub a call at Corvettes Etc. in Charlotte (704-394-5150), Im sure he can align it for you or he may just give you some tips on the phone if he cant get it in the shop in a timely manner.

Thanks Chip, I keep forgetting about Dub.  I'll give him a call and see if he has any advise before I bring it to him.  New seals are coming tomorrow so I hope this helps.

If you have an assembly manual, they have a detailed page on how they are aligned from the factory.