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How do you replace broken door handle on passenger side door of Chevy astro van?
Wiki User
∙ 12y ago
Just fixed my the easiest way. Remove bottom screw through existing round access hole. Cut a hole in the side of the door adjacent to the top screw. Make the slot big enough to get your finger and a wrench into it. Remove the top screw, disconnect the rod on the old door handle by pushing the tip with a screwdriver, remove old handle. Install new handle. It is easier to pull the latch to open position to get it into the door and behind the long lock rod. use needle nose or screwdriver to align and push latch rod into latch BEHIND long lock rod. Put the nuts back on screws, tighten, test, latch. Viola. Patch new hole with metal plate or Duct Tape.
Wiki User
∙ 12y ago
Wiki User
∙ 11y agoIf I remember correctly the hinges are welded to both the body and door.
IF that's the case then the door hinge pins will need to be removed to take the door off.
I usually use a floor jack with a 2x4 board on the bottom edge of the door to help support the weight. It also helps if someone can steady the door while the pins are removed/replaced.
Before you remove the pins there should be a spring located on one of the hinges. The spring should be removed using a tool to compress the spring for removal. BE CAREFUL as the spring may not look very big but can come flying out under a fair amount of pressure.
The hinge pins should be held in place by a combination of a knurled shoulder and spring clips.
The spring clips will have small fingers opposite of each other that will need to be squeezed toward the pin.
Then you will need to tap (pound) the pins out.
Don't be surprised if the pins and/or bronze bushings are wore out and need replacing.
You should be able to take the pins and bushings to any auto parts store for replacements.
Installing is pretty much reverse order of removal.
Place door on jack/2x4.
Install pins/bushings.
Install spring.
Wiki User
∙ 15y agoMy plastic handle broke three times before I found this site that sells aluminum handles and gives detailed directions on installation. http://www.thirddoorhandle.com
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