Taking Apart The Door - Maintenance and Repair Forum

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Taking Apart The Door
Sunday, April 06, 2008 10:56 AM
The two rear doors on my 99 Sunfire don't open. I've take the door panel apart from the inside and taken a look. From what I can see, the handle isn't attached to the metal rod that allows for the door to open. The lock rod is still intact, but the actual handle is disconnected.

I was going to pull the panel completely off and take a closer look and see what I could do. Unfortunately, my car has the manual windows. There is a crank in the way of the panel so it won't just come off.

What is the best way to get the panel off? I don't want to break the crank off because it'd be nice to be able to roll those windows down. I wouldn't mind replacing the crank itself if I have to, but I don't want to have to bother with fixing the mechanisms that allow the windows to be rolled down (if that makes any sense...).

Another obstacle in the way of the door repair is a metal sheet that is right around the handle and lock switch. The rod that connects to the handle is behind that and I didn't see a way to temporarily remove that. It seemed to have been bolted on from the other side. What can be done to remove that piece? Does it even need removed? I considered rigging up a hook and just trying to maneuver the displaced rod back onto the handle somehow. I don't know if that would even work, but I'm up for trying just about anything.


Thanks for the help! I'm hoping that I'll be able to get the doors fixed myself so I don't have to take my car to a shop and pay boat loads of cash for labor expenses. If not, I'll ask around for an estimate on how much it'd cost to fix.

Re: Taking Apart The Door
Sunday, April 06, 2008 6:01 PM
The plastic window crank handle should have a small paper clip like, u-shaped pin holding the plastic part onto a geared metal piece that operates the crank. To get to the clip, you might need a special tool or you can try needle nose pliers. It will be hard to see because it will be between the plastic crank handle and the door panel.

The operation leading to open the doors from the handles is weak. It is a small plastic circle that holds the actuator rod in place to the handle. Mine broke when I was trying to change out the door due to some body damage. Its a PIA to change...and I recall the handle being pop riveted in.

Good luck




______________________________
'99 Cavalier Z24 Convertible
Remind me why i keep this car?
Re: Taking Apart The Door
Sunday, April 06, 2008 8:11 PM
Thanks for the input. I had my brother pick up a handle remover. I tried it out but couldn't get the crank to pop out. Is the retaining clip right at the base of the handle? I've been putting it between the handle and the carpet trim on the door panel.

Once I get that off, is there any easy way to remove the shield that sits near the lock and door handle? If not, would that be something that I could break off and discard? I can't see the purpose that it serves, but I would hate to break something that is required for the door to function properly.
Re: Taking Apart The Door
Sunday, April 06, 2008 8:59 PM
take a shop rag, and work it into the crack between the window crank and the door panel then work it in there in a sawing motion and the clip will come out, you may have to try it from different angles..


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