Here's the answer to my own post...
[color="red"]FIXED!!! [/color]
Found the problem – when I reinstalled the White microswitch lock wire to the DS handle, I inadvertantly looped the wire around the wrong side of the window channel! It is VERY easy to do as the wire drops into the dark chasm of the door when it is disconnected.
Everything worked fine until I raised the window and it UNPLUGGED the connector at the bottom of the door – very hard to see it.
What threw me off was the LED’s in the DS door actuator started flashing after I set the ALARM from the PS – the LED’s are powered by the door lock actuator which still had power. Only the DS microswitch wire was disconnected at the plug.
Good thing is that now I can take the DS handle off the door in > 1 minute and actually put it together in under 5! The secret is to take the power lock actuator and metal cover plate off – then it is relatively easy to get your hand inside and actually feel / see what you are fishing around for! Once the black plastic ball joint “deflector clip” is lined up, you can insert a long ¼ flat blade screwdriver though the small rectangular hole in the door panel and lever it against the door panel and window channel to “pop” the clip back on. It’s also the easiest way to disconnect it too. Those clips look pretty fragile, so I don’t imagine they would stand too much twisting etc before they break. The factory manual shows a method all from the outside, but I cannot see how that is possible.
Hint #2 - get some 2" wide painters masking tape and apply a few strips above and below the door handle before you start to save the paint. It doesnt hurt to do the same with 3/4" tape on the handle either. Saves scrathing the surfaces!
I figured out that you need hands the size of a 5 year old to work on these cars….