Any problems in particular I should prepare or look for? Hope it's just a simple straight forward job, how long would you expect it to take? All interior panels are already off, I just upgraded my regulator.

 

See if after you remove the handle the replacement can be installed with the 'rod and clip' attached to the handle. If yes then I'd think it easier to drop the rod into the latch. I put may car back together in '03 after a repaint and I certainly don't remember.

 

I hope you have tiny hands! When you have your hands up inside that cavity, you can't see what you're doing!

 

trying to jog my memory. it's been a couple years since my PW upgrade, but as I remember, I installed outside door handle first without any rods attached. there are two speed nuts securing the handle, and just for the hell of it, a drop of (blue) thread sealer to secure the speed nuts. install the latch/lock mechanism with the two rods attached to the inter side door jamb (three screws). now the tricky part and where it helps to have small hands - position the two rods, and attach them to the door handle and secure with the two nylon clips. note, the shorter rod is secured to the latch mechanism with a metal locking clip, and the door handle with a nylon clip. the longer rod is held captive and somewhat "floats" in the latch/lock assembly. finally, and I really don't remember if I installed the power door lock harness/lock pawl and "c" clip before or after I installed the door handle, but i'm leaning toward, after, and maybe before the latch/lock mechanism. suggestion - trial fit all components on your workbench first, getting familiar with how everything goes together. when you have a good feel for it, only then attempt an actual installation. it's not an impossible task, just a PITA. reference page 10-16 of the FSM. remember, it's just a big puzzle - you have to figure out what assembly sequence works, and what assembly sequence doesn't work. I sure would like to see the manufacturing engineer's process cards for that work station. probably makes the whole door assembly look pretty simple. just think about it - there were folks putting this stuff together under the clock and on a moving assembly line, knowing the right sequence of events is the key to all this. just need to figure out "how." time wise, depends on several factors, but if you have a good feel for everything, i'd think you could install the handle and latch pieces in less than an hour.

edit: more memory jog - not 100% sure I got this right. the power lock harness and pawl has to be in place before the shorter rod gets attached since it attaches to the lock pawl. I don't think the door handle recess in the outer door skin will allow anything but the handle itself to be installed in the door. seems to me, installing the door handle requires pulling on the actual handle (as if you were opening the door) and sliding the pivot points up into the cavity, and then pivoting the whole assembly down to allow the two mounting studs and the lock cylinder into the door skin cavity - ??? as I said, a sequence of events - ???

 

Does the lever on the door handle only control the TDS? If I connect all wires, mainly the solenoid, will the handle still open the door?