How do you fix a car door lock of a Chevy aveo that fell into the door?

Answer 1

This is a funny question only because my wife just went thru this with her Aveo. Not as difficult as it seems. May take about an hour to take off and put back on. Here is how to fix it if you do not have power windows and locks.

On the inside panel:

1. Remove the three screws at the bottom of the door

2. Remove the screw that holds the door handle in place

3. By the arm rest, there is a little plastic round cover. Use a flat head screwdriver and pop that cover off.

4. Behind that cover is a screw. Remove it.

5. Go to the window crank and push in on the panel.

6. When you push in on this panel, you will see a small C clip holding the window crank on. While still pushing on the door, use something to push that clip down on one side to pop it off. Don't worry about the clip moving, because it won't.

7. Now remove the window crank and that small plastic piece behind it.

8. Gently start pulling the door panel off around the edges. You will hear a bunch of clicks. Don't worry, that is just the clips that hold the door panel on releasing.

9. Once you have freed the door panel all around, all you have to do is pull up, kind of hard, and the panel will lift up. Be sure to watch out for the door lock and right under neath the mirrors where the panel is tucked into. The door handle will be a bit tricky, but work with it, and it will eventually come thru the hole in the panel.

10. When you finally get this panel off, you will notice that there is a white plastic all around the access holes of the door. Pull back the top left portion of this plastic.

11. Inside by the door handle you will notice that the door panel is suppose to be held on by two screws. The one in question holds down the lock mechanism, and the other holds down the door handle.

At this point, you can do one of two things:

• 1. If you hear the screw at the bottom of the door, pull the plastic back at the bottom, reach down, and grab the screw and reinstall in the missing spot.
• 2. If the screw has disappeared (like mine did, of which, I have no idea how) then you will have to take the other screw off, take it down to a hardware store (Lowe's or other type) and get a new screw and washer. Trust me, they will have it. You just have too look.

12. Reinstall the screw making sure it goes thru the bracket that is coming off of the lock mechanism first and then into the door handle to hold them both in place. The nut will tighten with a 10 mm wrench.

13. At this point work in the reverse order and put the panel back on the car.

When reinstalling the door panel, be sure to make sure that the door lock is lined up correctly before forcing the panel back down on. Keep working with the door handle too, as it will eventually come thru.

Helpful comments from other contributors:

• Took me 20 minutes with these excellent instructions. I would add that there is an access hole right below the door lock that you can insert a 1/4 socket and extension through and lines right up with the bolt hole. Also it is a good time to tighten the 2 screws that hold the interior door pull on since you have the panel off. Mine were almost falling out. Also there is a small round trim ring around the interior door handle. It can be popped off with a small flat bladed screwdriver so you don't have to remove the door handle at all. Just be careful with it because some of the tabs are molded opposite of what you would think.
• Note that when you are sliding the panel off and on, what you are doing is hooking the top of it over the frame where the window meets the panel. The last part to slide off is the part where the side view mirror cover is and you just need to play with it a bit. When you re-install the panel, slide it under that cover and then hook the panel on.
• The tip about the trim ring is excellent. You might want to order a few panel clips from your dealer before you attempt this procedure, as they are brittle and tend to break.
• For #6 above: don't try pushing on the 'C' clip at the end(s). I found it much easier to pry it open using a flat screwdriver from its mid-point. Just lever the little wire and the handle pops right off. The 'C' clip might fly away, so watch carefully and retrieve it.
• Also please note it is best to do this entire procedure with the window rolled up fully closed.
• Helpful post. I just finished this task on a 2005 Aveo with power windows. The power window switch is not held on with clips so do not try to pry it out. It is screwed on from underneath the switch and does not need to come off the door panel for this job. Pop the door panel loose after removing screws per your instructions - you should also remove the black triangular plastic piece covering the driver side door mirror/manual adjuster. It pops out easily using a screwdriver or interior trim tool. Reach up inside the door panel from the bottom and disconnect the power window switch (large white connector with push to remove on one side) and mirror switch (if so equipped - smaller connect up higher with push to remove on one end). At this point the door panel will be held in place by the door handle. It is possible to pull the round door handle/trim through the hole in the door panel but it is not meant to come off this way. I could also not get the round door trim to pop off per Max's post. I ended up reaching behind the door panel from the top and disconnected the actuator rod from the door handle by pushing up on the small green clip that forms a half circle where the rod meets the handle.
• I could not find the missing screw until I dropped the replacement screw I was installing. Both screws ended up in a ledge created by a V shaped brace on the sheet metal of the door about 3 inches below the mounting hole. Take a small screwdriver and sweep the ledge created by this brace from back to front and you will likely find it.
• My door lock rod (attaches to the door lock you are trying to put back in the hole) was badly bent - most likely from the power window hitting the door lock that was dangling inside the door. I had to take the actuator rod loose - similar to removing the clip at the door handle in order to be able to put the lock in the hole. I was able to bend the rod back into place by hand - the first time I tried there was too much tension on it and the lock would not function properly. Second time was the charm. The door handle was a problem when replacing the panel. I reconnected the actuator rod clip with the handle on the outside of the door panel. There are two large plastic clips at the front ot the handle trim that are designed to go into slots on the door. They will not line up properly and will hold the trim away from the door. In that position, just hit the front of the door handle trim sharply with the palm of your hand and they will pop into place. Then install the screw into the handle trim. I wasn't able to do this in 20 minutes (maybe next time) but it is easy and takes less than a hour.