The Ultimate Door Thread (Up to Model Year 2000)

[mattthebrat]

I have seen many questions asked about taking apart these doors, so as long as I had an extra door to play with, I decided to do a write up on it!!
If there is anything I missed or didn't explain enough, feel free to ask me or correct me.

Removing The Door Panel

1. Remove the inner handle trim by prying from the inside out, like this:

There are four tabs that hold the bezel on (Red Arrows)

2. Remove the light by prying out on the back and then pulling the light backwards out of the hole.

3. remove the two screws in the armrest:

4. Remove the switch panel by prying up. Be careful of the plug on the mirror switch. Many people forget about the clip(Red Arrow), or just say screw it and break it off.

5. If you have crank windows you will need a crank removal tool. They are about $10 at any auto parts store, or you can build one yourself, like I did.

6. Remove the filler panel by the mirror

7. Pop the plastic clips out, a clip tool may be helpful for this.

There are 9 clips that hold the panel to the door (Red Arrows)

Now just pull up on the panel and push in at the top to release it from the window channel.
And thats it!!

 

[mattthebrat]

Removing Inner Door Handle

1. After removing the door panel, drill out the 3/16" rivet (Red Arrow) then slide the handle assembly forward.

2. Remove the clips holding the rods on by sliding them away from the rods and off of the tab. Save the clips for the new handle.

3. Reinstall using either a bolt or a new rivet.

 

[mattthebrat]

Outer Door Handle

1. Make sure that the window is all the way up.
There are 2 10mm bolts that hold the handle on.

The inner bolt can be reached without removing the inner door panel, through the hole. (Yellow Arrow)

2. Remove the three Torx screws that hold the latch in place.

3. Pull the handle out, front first. It helps to pull up on the handle (like you are opening the door) to clear the top of the hole.

4. Remove the clips holding the rods on by sliding them away from the rod and off of the tab.

5. On reinstallation make sure that the latch actuator rod is facing the correct way, or it will jam the handle.
__________________

 

[mattthebrat]

Latch

1. Remove the 3 7mm screws holding the plastic vent cover on

2. By rotating the latch 90 degrees it will slide out the vent hole complete with the rods attached.


Mirror

1. Remove the foam plug covering the mirror bolts.

2. Remove the three 10mm nuts

3. Disconnect the wiring plug

 

[mattthebrat]

Inner Door Panel

1. Run the window about half the way down.
I made a connector for running power windows on a door that is off of the vehicle. I cut the plug out of an old wiring harness and put two spade connectors on the end so that it can be connected to a drill battery.

2. Remove the 10 7mm screws (Red Arrows) and 1 10mm bolt (Yellow Arrow)

3. Slide the panel forward and then backwards to release the rollers from the glass track.
You may have to reach in and bend the tabs down on the glass track.

4. Unplug all electrical connectors and pop the wire clips out of the panel.

 

[mattthebrat]

Removing The Window

1. Remove the second 10mm bolt holding the window track to the door.

2. Tilt the front of the window down and out of the front track, then forward and out of the rear track.

3. Pull the window down and forward at a diagonal to pull it out of the door.

Thats it, now your down to just sheetmetal!!

Good Luck

-Matt-

 

[625fireman]

Nice write up Matt.

 

[Matt Bachand]

Excellent job. Next do one for the grille!

 

[Gunner0812]

Nice write up Matt.

x2!

 

[TurboTahoe]

I hereby make a motion that this thread become a sticky. Any seconds? All those in favor?

-Rob

 

[BigArt]

Sure I second that. :iagree::thumbsup:

 

[chevyCowboy]

where is the best place to buy the channel and rollers that the window sets in?? the channel on mine is badly rusted and the rollers dont roll so well keep having problems geting window up or down

 

[Matt Bachand]

where is the best place to buy the channel and rollers that the window sets in?? the channel on mine is badly rusted and the rollers dont roll so well keep having problems geting window up or down

http://www.rockauto.com/catalog/moreinfo.php?pk=632717

If you mean those try rockauto.com

 

[mattthebrat]

where is the best place to buy the channel and rollers that the window sets in?? the channel on mine is badly rusted and the rollers dont roll so well keep having problems geting window up or down

There are two channels, one comes as part of the inner door panel, and the other is part of the glass. The one on the glass is glued on, if you are VERY careful you can peel it off, and urethane a new one on. No one sells them new, but many junk yards keep them off of broken windows,

 

[HighSierra86]

I hereby make a motion that this thread become a sticky. Any seconds? All those in favor?

-Rob

In favor!!!

 

[chevyCowboy]

There are two channels, one comes as part of the inner door panel, and the other is part of the glass. The one on the glass is glued on, if you are VERY careful you can peel it off, and urethane a new one on. No one sells them new, but many junk yards keep them off of broken windows,

thats the one i new there had to be a reson i couldnt find any at parts stores

iv got an extra door i guess i ll just have to tear it apart and see if its any better than mine

thanks for the rollers i looked and couldnt find them

 

[packratt]

Dealer should have that channel. LMC may have it as well, can't check catalog is 6 hrs away.

 

[Pruittx2]

When doing body work and having to pull the outside door handle for the painter,, I would pull the 3 7mm screws from the plastic vent assem under the latch, and reach up in the door with at 10mm ratcheting wrench to pull that inside door handle bolt. when the door handle comes out a little bit, go under the handle on the outside, with a small screwdriver and push up on a tab at the bottom of the lock cylinder to let it slide out the back side of the handle, and unclip the rod at the latch assem, and out it comes,, with out having to undo all that door panel crap.

I've had to do it like 300 times or so in the last 20 years!

 

[RI Chevy Silveradoman]

Just for accuracy purposes, what are the model years that this DIY write cover? Up to 2000?

 

[mattthebrat]

Just for accuracy purposes, what are the model years that this DIY write cover? Up to 2000?

It covers the 95 to OBS-2000 trucks and SUVs