How do repair the handle on the inside driver's door of a Chevy Tahoe so it will open the door?

Answer 1

[Thanks for this great article. This worked on my 1997 Tahoe in about 1.5 hours with a few amendments noted below. Basically, I left the poppets attached along the bottom of the door panel, did not disconnect any wiring, and did not mess with the plastic sheet that was in place. There was sufficient access through the hole in the door panel for me to drill out the rivet. I would recommend using something to catch the drill debris so it doesn't collect at the bottom of the door panel. --CyberRoy]

This worked on my 1996 Tahoe, I amended a few things that stumped me briefly.

The door on my 1998 Tahoe would not open, the handle didn't seem broken but...it was. Below is how I remedied the problem. Including my trip to Autozone (door handle) and Lowes(screw) this project took me about 1.5 hours and cost about $18.

The most you will need is:

• Flat head screwdriver
• Poppet remover (optional)
• Socket set
• Drill and bits
• New door handle
• Superglue
• 12-14mm x 1/2" screw
• Pliers
• Hammer
• Flashlight

Notice I said that is the most you will need.

To remove the door panel:

1. Take off the triangular piece at the top front of the door--it is held by one poppet (This just lifted off by pulling upward. Like many of the 'poppets' on my truck, this one separated from the triangular piece without the poppet pulling out as designed.)--A poppet is a plastic fastener that is commonly used to connect door panels to the door frame. For this application they are roughly 1-1/2" long. Don't worry when you are prying on them...they will sound like they are breaking. (Many will remain seated and the plastic piece they are anchoring will just pull away from them. They aren't broken and you will need to pull them out and to get everything back where it was.)

2. Use a socket wrench to remove the two bolts in the pull handle (the handle you pull on to close the door, not the handle you open the door with)

(I then removed the ring around the door handle. Put a screwdriver along the inside edge to remove the 3 clips. One on top, one on either side).

3. There are around ten poppets' spaced around the edge of the door panel; using a screwdriver or poppet removal tool pry these loose. Be careful not to damage the door panel. (I couldn't get a screwdriver to pop these off. I started at the space where the 'triangle was removed' and just pulled til I got one to separate, then I lifted up on the door and the felt edged window guard pulled away. Probably only 1/3 of the poppets actually popped out. The rest just disengaged from the door panel. I went back with vice grips and pulled the poppets out and put the male end back in the door panel so I could replace it at the end).

[Alternate flow for step 3. Remove the poppets along both sides and lift up on the window guard to free the top of the door panel. Leave the poppets in place at the bottom of the door panel. If you can get to the rivet at the base of the old door handle assembly with a drill, then you can skip steps 4-6 below. Proceed with steps 7-9, then 10 without the need to superglue anything. --CyberRoy]

4. When all the poppets' are loose shimmey the door panel straight up until it is loose. Be careful not to puncture your speaker with one of the poppets'. It is hung on the top of the inside door panel where the window goes down.

5. Now take your time removing the wiring from the switches, light, and speakers...you do not want to break these connections. Some of the connections are tricky so be careful...you will probably need someone to help you by holding a flashlightand the door panel. (I read another answer and removed the wiring after popping off the control panel first, even before disengaging the door panel. Start with the edge closest to where your leg would be) None were really 'tricky'. Some required that you depress a clasp, most required ginger prying and pulling.

6. Peel off the plastic water shield (plastic sheet) behind the door panel, try not to stretch or tear it. (none on my 96)

7. With the door panel removed you can see that the door handle is held by a rivet, so you will need to drill it out. Just get a drill bit slightly larger than the rivet hole and start drilling, the head will break off and then you need to hammer the rivet back through the hole. You may need to use a chisel or screwdriver to knock the head off if it gets stuck.

8. Now slide the door handle back and then down and it should be loose. Remove the linkages from the handle, you may need to use pliers, but do not bend them you could mess up how your door opens.

9. Attach the linkages to the new door handle and use a metal screw slightly larger than the rivet hole to reattach, I think I used a 12mmx1/2" screw from Lowes (it may have been a 14mm).(A 1/4 X 1/2 " round top flat head screw work for me)

10. Use superglue to put the plastic water shield back on the door. Now reassemble the door and voila.