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Hi, I'm Mike Green. I'm one of the owners of 1A Auto. I want to help you save time and money repairing and maintaining your vehicle. I'm going to use my 20 plus years experience restoring and repairing cars and trucks like this to show you the correct way to install parts from 1aauto.com. The right parts installed correctly, that's going to save you time and money. Thank you and enjoy the video.
Ok so we're going to replace the outside door handle on this 1996 Chevy Tahoe. This is exactly the same for any '95 to '98 GM truck or '95 to '99 Suburban, Yukon or Tahoe. You will need to see a couple of our other videos where we take off the door panel and the interior door panel just because it's kind of involved. It's not difficult but there are quite a few steps to it. Basically you have to remove the interior door panel and then the panel that holds the regulator and lock actuator and then to get to the door handle itself.
As you can see the tools that you need aren't that complicated; 7 mm socket and ratchet, a Phillips screwdriver, flat blade screwdriver, a putty knife or a door panel clip tool and a 10 mm socket and ratchet. Ok the bulk of the work on this repair is actually taking the door panel off and the interior door panel off and I have those videos as video responses to this video. Where we're going to start actually is you've basically taken the interior door panel off and the panel with the regulator and everything off and now you use a T-30 torqued driver and you really need a bit with a socket like this and a wrench or a ratchet handle. You don't have to have an air ratchet like I have but you need a ratchet handle to put enough torque on those to get them out so you remove those and then go from there.
Ok so I've raised my window and I've secured it with plenty of painters tape. Now you want to remove that 10 mm bolt and this 10 mm bolt. Ok now looking in there you can see that there's a clip right here and you see I've got it pried away. You've got to pry it; there's a hole right there and there's a tooth on the clip so you have to pry it away and up and then you can get that rod out like that. Good, now those bolts are undone. The panel comes up and out and this rod comes with it and then here again, we'll take the screwdriver and pry out this here and then push on the clip and then the rod comes out. Ok so you've got your new handle; make sure you've got your clip on here. This face should be on this side so you push the rod into it, make sure you've got your clip on here. Take this rod it's got the well on this part has a little red end and push it into your door handle and lock it. Then put it down in, up and on. Ok so here's our one 10 mm bolt.
I just have those on there hand tight. Now here's the lock mechanism and I'm going to make this look easy, nope. You want to bring it up into place and guide your webbed rod right into the hole. Ok so upon editing I realized that you couldn't really tell what I was doing in that shot. Basically, right in where that circle is in behind that weather strip the rod that was painted red at the bottom that you attach to the door handle comes down and you're lifting up the lock mechanism and making sure that rod goes down into the hole that's on the lever right in there. Obviously you'll know if you get it right because if you do the door will work; if you don't the door will not open. Make sure that all your doors are not locked when you test; basically it's a good tip for any time.
Then hang it up and put one of the 10 mm things in there. Ok I'm just going to tighten that up a little bit. Put another one in place. Now I'm going to take this rod, once you get it in get it started then take your hand out and reach in with this finger and push the rod in the rest of the way. Now I've got everything on, not quite tight yet I'm just going to test it real quick, that's good. Lock, unlock, ok. Now I'll tighten up the bolts in the handle and these two 30 screws and get the door back together.
That's basically how you do the door handle from this point on it's pretty much reassembling everything. Once you've taken it apart it's usually pretty easy to put it back together but we do have the videos on installing the door panel and the window regulator and lock actuator plate so you can either search our other videos or check out the replies to this video.
We hope this helps you out, brought to you by www.1AAuto.com your source for quality replacement parts and the best service on the internet. Please feel free to call us toll free 888-844-3393. We're the company that's here for you on the internet and in person.
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Now, before we start this job, it's important to make sure that you have your window in the up position, it's going to make it much easier overall. So, to start getting the door panel off of here, we're going to need to remove some stuff. You're going to have a couple of little plugs here, and those are covering some Phillips head screws. So, I like to just pop those out with my flat-head screwdriver. Now we're going to use our trim tool and we're going to remove this outer plastic piece here to do that. There's going to be a little clip hidden inside there, there, and over here. So, I'm just going to start right along here. Continuing with our plastic trim tool, we're going to lift up on this plastic piece here, starting from the rear. There we are. Let's disconnect all this wiring. Switch right here, just pull that right out of there.
The next thing you're going to want to do is remove this area right here. Yours is probably going to have a nice lens cover over it. Ours is broken. You just kind of come right down along the corner here and you should be able to pop it off. And then we're going to disconnect the wire. Lift up on that. Separate the two. Now, we're just going to use a little forkey tool to remove this push clip right here. Now, we'll move along up to here. Now, we're going to remove this piece right here. It should pretty much just lift straight up and out. There we are. Now, let's continue with our trim tool, we're going to come right down along the bottom of the door panel, and try to break it free. Put the wiring down in here, lift straight up on it, remove the panel.
So, the next thing you'd want to do is slide this. There's a little area right here that looks as though it should have a screw. Ours does not. But if there is one, just remove that. And then once you do, you should be able to slide this and then draw it away. Right behind here, you're going to see the rods that run right along here and connect over there. We're going to disconnect them from the backside of this. Just pull this out to where we can see. I can see this rod. I'm just going to come down with my nice small screwdriver and just try to separate these two parts. There we are. Do the same to the other one, of course.
Next, it's going to be time to remove the speaker. There should be a screw here and there. Ours are missing, but remove those two screws. And then right here, there's a little tab, push on this, and then you should be able to pull the speaker away from the panel itself. Now, we're going to disconnect the wiring that goes to it right there. Let's tape up this window. The next thing we're going to do is start carefully pulling this plastic back. And this is so that we can get to all the wiring because we want to make sure that we can disconnect it and have it nice and safe after we take off this panel. There we go. That looks pretty decent. So, now, we're going to remove this plate right here. You're gonna notice that there's a whole bunch of these mounting bolts right there. They come all the way around. All of them are the same in exception of the one right here.
We're going to carefully try to move this around just to see if it breaks free. You want to keep in mind that the window regulator is mounted to this plate and the window regulator also is attached to the glass up here. It has a couple of little rollers that are going to go into a track. So, if we were to pull this down, we could, of course, pull a tug on the window, which might pull it down, the window's glass, so obviously, you want to wear eye protection. Safety is the number one concern.
The next thing we need to do is remove the rivets that are holding the window regulator to this panel. You can do that with something like this, with a drill and a nice drill bit or you can do it with something like this with a nice cutoff wheel. Obviously, if you use a cutoff wheel, you might, you know, nick this area around here a couple of times, in which case, you would just paint over it and it's not that big of a deal. That looks pretty good. I'll punch the rest of that out.
Hammer and punch, go right for the center there. Okay. Those popped out. One more here. There we are. The window regulator can move around. If you look right through here on the panel, you're going to see where the rods kind of are secured to the panel itself. You should be able to push those away. There's one right over here as well. Awesome. Let's remove this bolt. So, now, you have the rod that comes through this right here. We're just going to pull that right down. Okay. This is looking good. Now, we're just going to let this dangle. Obviously, you want to make sure you don't put any weight on any of the wires. We don't want to give this any tugs. We're going to grab onto the window regulator. Just slide it towards the front. And then we should be able to kind of pull it down assuming I can get it out of there. So, now, we just need to disconnect the wiring for it. Squeeze right there and draw it off.
Now that we have a clear view, we can remove this 10-millimeter right here. And then if you were to look on the outer portion of the door, you're also gonna see another 10-millimeter. So, now, I can move the handle around and you can see this little metal clip right here. That's what's holding in this rod. If you come right down along here with your pocket screwdriver, there's a little tab. You just kind of pull that out in a way, you can bend it a little bit, and then you should be able to lift up on this clip. There it is. Then once that's up, the rod should want to come right out of there. Now that we have all that out of the way, we're going to remove these screws so we can get this off of here. So, now, we can move this around. I'm going to see if I can get this up and out of here.
Now, I'm just going to draw up on that rod, pull this right out. So, now, to get the lock out of here, I'll turn it over. If you look right here, there's kind of like this little slanted angled piece and that's the lock that holds the lock into the handle. To get this out, we're just gonna come right under here and try to lift up on this plastic, and then I'm gonna use something nice and flat like this bit driver, and I'm gonna press on the lock part and just try to push it through. There we are. Now that we have that lock out of the way, I'll come right down here, bend that. That's our rod. I want to make sure that it goes back in the same direction that it came out. Do a quick comparison to make sure you're dealing with the same part. This looks perfect. We'll set this aside to be recycled and we'll continue.
Now that we have that lock in there, we're going to make sure we get this rod back where it came from. In case you were trying to remember which way it goes, if you were to look at the backside, you would see there's little ears, that's what's supposed to hold on to the rod right inside that groove. So, we'll just shove it through. Once it goes through, just give it a nice little tug, and make sure it's locked in. That's great. Let's get this on the door. Okay. That looks great just like that for now. So, now, we need to make sure that the red rod that's coming from the handle is going to slide down into the slot on the latch. And you also want to make sure that once we get that done, we put this on there as well.
So, now, if we move the handle around a little bit, we can line up the rod with the hole down in there, and then we're going to carefully get this handle back in. That looks good. Let's take our little bolts. Start that one in there and then, of course, the one on the outside right there. Now that they're both started in, let's go ahead and snug them up. This is sitting perfectly. So, now, let's just go ahead and start in these bolts for the latch. Just a couple of threads. Snug these up. So, now, we're going to get this rod back up onto there. Let's try and get this on there. Oh yeah, that looks good. Give it a nice tug, make sure it doesn't fall right out. It's clipped in good. You can see that you have your two rollers that are facing in the same direction and then you have one that is not. The two that are facing in the same direction are going to be the two that go up inside the upper channel up here.
So, what we're going to do now is we're going to put the first one through and then we'll put the second one through and we'll let the window regulator hang just like this. The next thing we need to do is get these rods. These are gonna go in between the window regulator and the panel itself. Something else that I want to show you before I put the panel up is this wheel right here is going to go inside the track that's on the inside of this door panel right there, okay? This little piton right here is going to go inside of this piece right there through the bottom. This is all going to be inside the door panel so it's going to be hard to see. So, I'm trying to let you know ahead of time what's going on. This goes in the track, this goes in the piton there, okay? We'll lift these up, get this thing so it's kind of sitting where it's going to need to go. I'm just kind of resting the rods up here, where hopefully they'll stay for a minute. Now, I'm going to get everything else lined up.
Get this back inside of its groove. Just make sure that the two wheels up on top are sitting inside the groove where they need to roll. That feels perfect. Rollers are up here, rolls back up. I'm going to put the one with the piton in now, slide that right up and in there. The other rod is going to ride right in underneath that one. So, we'll just put them both so they're kind of up here for now. So, now that we have the window regulator and the rods lined up perfectly, we're just gonna take this, I'm gonna put one bolt in, lift up on the panel, make sure that these ears go over the panel that's on the door there. It should sit right in there. I'm gonna slide my window regulator around till I can find my rivet holes. We've got one there, there, there, and there. Perfect.
The next thing we're gonna need is some of these right here. Nice, beautiful rivets. These are 1/4-inch. We're gonna need four of them. Slide that in and through there. I like to start them all in before I tighten any of them up. That way there, I know that it lines up overall. Now, before you rivet this in, it's important to double, triple, quadruple check to make sure you have everything on the inside of this door panel set up right. You need to have the rollers in the channel up along the top. You need to have the roller in the channel that runs along here. You need to have the rods sitting inside the little piton area on that unit that I showed you and coming up in this direction here so you can get to them. Once you've done that, you also want to make sure that the wiring for the window regulator is plugged in and then we can continue on by using this right here and putting in these rivets to hold the window regulator to the panel.
Just make sure the rivets don't fall out. All right. That's a good sound. It means we're at the end of that rivet. At that point, you can of course trim off the excess. We'll do the same to all.
The next thing we're going to do is cut off these little ends here. I like to use my cutoff tool. I'm just going to come along the top here and put in a few of these bolts to try to hold this panel still for a minute. And then we're going to test the window regulator ahead of time before we continue on any further. That way there, if there's any problems, we can fix it now. Click this in. Get the key in the on position. I'm going to try not to tear this tape because I might have to reuse it. I'm hoping that I won't, but we'll see. Beautiful. The window is going up and down the track perfectly straight. It's going down when I tell it to go down, it stops when I tell it to stop, and it goes up when I tell it to go up. This is perfect. Let's get the tape off of here and continue.
So, now, let's check to make sure that these rods are working perfectly for the latch and, of course, for the handle. I'm going to start with this inner one. I'm going to pull the rod that has the little piton that goes to the locking mechanism inside here, the electronic locking mechanism. I'm going to pull that towards the front of the door. That's the unlock position. Now, I'm going to grab that other rod and I'm going to push this up. This is simulating that the door is in the shut position. I'm going to pull on that rod and this should come down. That means that I can open the door now. Let's go ahead and shut that door. I'm going to do it again. Give the rod a pull. Awesome. Okay. Flip it back up. Now, I'm going to take that first rod with the piton for the locking mechanism, I'm going to push it towards the latches. Let's pull on that same rod that's going to work this mechanism here. Okay. That is not working.
So, now, what I'm going to do is I'm going to pull on this other rod, the locking rod, and now I'll pull on the latch rod again. That works great. Let's do the same over here. I'm gonna grab this outer handle. Right now, I'm in the unlocked position. So, I'm going to put pressure on this, pull on that, and it releases. Door's shut. I'm gonna lock it. Push on this, pull on the outer handle, okay, it's locked. I put unlock it. Awesome. This works perfectly. Let's continue. So, now that we know that everything functions as it should, we can continue on by bolting in the play here or the door panel. We're gonna use all of our little bolts and just go right along the outer area. I'm just gonna start them in and then I'll snug them all up once I get all the way around. Awesome.
Just reaching here, we're going to grab the wire for the speaker. Connect it in. Make sure we don't have anything on the magnet here. If you were to look at the speaker, you're going to see a little tab there and then there should be one here. We're going to come at an angle and slide them right into these little grooves here. Should slide in. Pretend that they're both in, press it, it should click right in. So, now, you would just, of course, want to get this back on here. For us, it's not gonna stick. You get yourself some butyl tape and get it to all stick back on there. It's probably a great idea.
Now, it's going to be time to install the inside door handle. If you were to look at the backside, you're going to see an area right here for the door handle rod and then an area right here for the lock rod. I'll grab those rods, I'm going to line them up. You can start with whichever one works best for you. I'll go with the one that's farthest away because I'll have the most amount of flexing action. Make sure it clicks in and it does not fall out. If it falls out, you have an issue. Next, I'm going to do the lock or the handle one. Obviously, it's very hard to get the right angle. Okay. I got it lined up. I'm just gonna squeeze it right in there. Give it a nice tug. Make sure it does not fall out. Now, we're just going to take this unit, we're gonna press it up so it's up against the panel and it's sitting in the grooves, and then we'll slide it towards the latch.
So, now, for good measure, I'm just gonna throw a rivet right in here. You could try to put a nut and a bolt and reach your hand back through there if you have to. Okay. That's nice and tight. I'll just cut this off now. So, we're just going to get this in here. It should have a nice little cover over it. So, now, it's going to be time to get the door panel back on. If you were to feel right down along here, you're going to feel there's a ridge. That's going to sit right over along the top of this. And then, of course, you have all these little push tabs that are going to go inside of all these holes after we've done that.
Let's grab our wiring, get that all ready. I'm going to click this in because now's the time to do it before I get this together. I've got my wires in my hand, I'm just going to kind of pull those through. Let's get this up onto here. Okay. Look to make sure your pieces all line up. There we are. Trying to get the cover on here. Let's make sure our door's unlocked. Should slide right over. A couple of loving bonks. That feels good. Let's get this area back on. Now, it's going to be time to get this reinstalled back into the door panel. We'll connect in our speaker wire, super important. We've got our mirror wire. Click it in, give it a tug. Get my wires situated here. I'm gonna turn this, slide it right in. This one, slides right in. Everything is nice and secured. You want to make sure the speaker wire is going through this lot and not over here, otherwise, it could get a pinch coming across there. To install this, you're going to notice you have a hooky-do right here towards the front area and then you have your clips right here that are going to latch right there. That being said, come in high and put in the front area first with the hooky-do. And then right here, give it a nice push. Couple of loving bonks. Perfect.
We don't want to forget about this. You've got your little clip here. And as you can tell, it slides down. You also have your hooky-dos there, they're gonna ride along this ridge right there. Come up nice and high, push in, slide down. Give it a nice tug. Make sure it does not rattle around and it's not falling off. We need a little clip right here. Now, it's time to get these two screws into the handle area here. Make sure it's nice and tight. Don't forget about your little covers in whichever hole you want, nothing special. Now, it's going to be time to test our work. So, you want to make sure you have the key in the on position, the vehicle does not have to be running. Let's go ahead and try to put this window down and then back up. The battery's a little low in this vehicle. Perfect. Passenger side. Oh yeah. Let's go ahead and test the mirror. Right side. Yep. Awesome.
Tools used
Hi, I'm Mike from 1AAuto. We've been selling auto parts for over 30 years! We're dedicated to delivering quality auto parts, expert customer service, and fast and free shipping, all backed by our 100% satisfaction guarantee. So visit us at 1AAuto.com, your trusted source for quality auto parts.
In this video we're going to be working with our 1996 GMC Sierra. We're going to show you how to remove and replace your vehicle's exterior door handle. If you like this video, please click subscribe. We have a ton more information on this and many other vehicles, and if you need this part for your truck, you can follow the link down in the description over to 1aauto.com.
Here are the items you'll need for this repair.
Remove the two Phillips head screws inside of the armrest on the door. Do this with a Phillips head screwdriver. To remove the bezel around the interior door handle, you need to kind of get in there with a trim tool or a flat blade screwdriver, and push down on the tab to release it. There are three: one at the top, one at the bottom, and one on the side.
Remove the extension at the top of the door panel by prying out with a trim tool. Using your trim tool, pry up at the back of the power window switch. Lift it up and pull back to release the hook at the front. Disconnect the connector for your tweeter. Pop up the tab on this two pin connector at the front of the window switch, and pop the connector out, and then push down on the tab for the main connector and remove that from the switch. I'm using a pick here. You could also use a small flat blade screwdriver or a trim tool if you had to, really whatever works best for you.
Using the trim tool, pop out on the door reflector and remote the connector. This is another one of the ones we'll have to lift up on the tab with a pick. Using a trim tool, pry out the bottom of the door. You may need to work it a little bit to figure out where the tabs are. You'll also need to pop out this pin at the top on the front of the door. Once all the tabs are out, lift the panel up and remove it from the door.
Peel off the inner water shield on the door. There's also a small piece over in the corner. Make sure your window is rolled all the way down. There are ten 7 millimeter screws around the perimeter of the inner panel. One under the speaker here that's a little tricky to see, and a 10 millimeter at the front. We'll need to remove all of those with a socket and ratchet. Pull the panel forward. Pull out the handle rod. It may help to have a tool to help you get some leverage on it. You'll also want to pop that out of its guide clip. Same thing with the lock rod down here. We'll also need to pop this out of its guide rod and pull it out of the lock actuator as well. Pop out the tab for the courtesy light in the door. Lift up on the cover for the door lock actuator, and remove that connector. You need to fish it out and around. Pop that retainer through, and then pop out all the rest of the retaining clips to remove the harness from the door.
You'll also need to unplug the window motor and the door speaker. Pull the harness through the door. Slide the door panel forward until the window roller is out of its channel, then slide the guide out of the back, and remove the assembly from your vehicle.
Lift up on the glass in the door. Bring it all the way up, and use some painter's tape to secure it in the up position. Move the 10 millimeter bolt on the door jamb side of the handle. You'll also need to remove the 10 millimeter bolt on the backside of the door handle. You'll need to remove both of the rods for the door handle, as well as the door lock. You may need a small flat blade screwdriver to help get the leverage you need to remove them. It's kind of tough to see, but you can sort of feel in there with a small screwdriver. Hopefully get enough leverage to pop that out. Remove the door handle from the door. Now just like you did to remove your lock rod, you're going to want to pry this clip up. You can just split it like I am here and remove the latch from the vehicle.
Here we have our old part that we removed from our vehicle, and our new part from 1aauto.com. As you can see, these parts are exactly the same with the same handle, same lock provision, the same latch mechanism on the back, and the same two bolt mounting locations. If your old door handle is broken, cracked, damaged, or non-secure in your door, this new part from 1A Auto is going to go in direct fit, just like your original equipment, and fix you up right.
Reconnect the door latch rod, and reinstall the door handle into the vehicle. Line up your door handle and reinstall the two 10-millimeter bolts. Pop the lock rod back into its clip.
Remove the tape that's holding your window up, and support the window from the bottom side, then carefully lower your window and allow it to rest on the bottom stop.
Reconnect your door speaker and your window motor, and send the rest of your wiring harness back through the door. Slide the back half of your window regulator back into the window track. Once the back is in, slide forward and install the front part of the regulator into the glass as well. Reconnect the door lock as well as the door handle. Don't forget to engage the lock actuator, and snap both rods back into their guides.
Realign your door panel. Reinstall your wiring harness. Make sure that all the tabs and retainers go back in their appropriate places. Make sure you run the harness through, and reconnect the door actuator as well. Lock the clasp in for your reflector, courtesy light, and reinstall the ten 7 millimeter screws around the perimeter, as well as the one 10 millimeter. Reinstall the water shield. Sometimes this adhesive doesn't really want to stick a second time, if that's the case, it's all right to put some tape on there to secure the edges.
Pull your wire harness back through the door and lay the top edge into the door frame. Line up the plastic containers and push them all back into place. Reinstall the inner door handle bezel by lining it up and snapping it in. Reinstall your reflector. Place the upper door extension into place. Reinstall the two Phillips head screws in the armrest.
Reconnect your door speaker as well as the two electrical connections on the power window switch. Slide the front hook into the door panel. Snap the back into place, and you're good to go.
