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I just went through it on my 96. I found it pretty straightforward. Disconnect the negative battery terminal as you will be disconnecting electrical wires in the door. There is a screw in the back edge of the door about at elbow level that needs to come out. There are 3 screws in the door handle area. Also remove the 2 screws from the cup in front of the armrest. The cup just pulls out. Pry down on the door light above the handle and pull the light out about an inch. Gently pry out the manual door lock from the door handle area with a screwdriver. Gently pull the door panel off the door frame releasing the plastic pegs at the bottom one by one. Next disconnect the wiring for the hatch release, power mirrors, and power windows behind the panel and it should come free. If it isn't coming loose you have missed a screw somewhere or forgot to remove something. The key is to take your time and be gentle with all the parts, don't try to force anything, if you did it right everything comes off easily.
As for the manual door lock, check how it is aligned, there is a place inside the plastic lock handle to accept the metal bracket that goes into the inner door lock mechanism. Also check that the metal bracket lines up properly without the plastic door lock lever on it. Check to make sure the 3 screws around the handle are tight. Everything should have a clean path with little resistance. It could be your power door lock is wearing out on the passenger side. Replacing that is a trickier job as you have to go deeper into the door to replace it.
Is there anything better than white lithium grease for the moving parts in the door? For the lock itself, I've used a spray lube from slick 50 in a red can. It's thinner than the WLG.
Just as 96polovette said. To make one thing clear, there is one screw located behind the window up/down switch. Pull the switch out and you will see the screw. This one took me forever to find....
Here is the location on my 93... The upper handle was loose, then broke completely. This is why I removed my door panel. To fix the handle, it just require a screw. You may want to tighten yours since it constantly being pulled on...
Last edited by 93*Corvette; Jan 9, 2007 at 12:41 AM.
[QUOTE=93*Corvette;1558436506]Just as 96polovette said. To make one thing clear, there is one screw located behind the window up/down switch. Pull the switch out and you will see the screw. This one took me forever to find....QUOTE]
This is the one that got me for quite a while.
As far as the locks both of mine were sluggish. The metal rod behind the plastic lever was rubbing and causing a bit of a bind. After straitening that out and coating all the moving parts in the door with silicone spray both locks snap quickly just like I would expect them to if they were new.
I just went through it on my 96. I found it pretty straightforward. Disconnect the negative battery terminal as you will be disconnecting electrical wires in the door. There is a screw in the back edge of the door about at elbow level that needs to come out. There are 3 screws in the door handle area. Also remove the 2 screws from the cup in front of the armrest. The cup just pulls out. Pry down on the door light above the handle and pull the light out about an inch. Gently pry out the manual door lock from the door handle area with a screwdriver. Gently pull the door panel off the door frame releasing the plastic pegs at the bottom one by one. Next disconnect the wiring for the hatch release, power mirrors, and power windows behind the panel and it should come free. If it isn't coming loose you have missed a screw somewhere or forgot to remove something. The key is to take your time and be gentle with all the parts, don't try to force anything, if you did it right everything comes off easily.
As for the manual door lock, check how it is aligned, there is a place inside the plastic lock handle to accept the metal bracket that goes into the inner door lock mechanism. Also check that the metal bracket lines up properly without the plastic door lock lever on it. Check to make sure the 3 screws around the handle are tight. Everything should have a clean path with little resistance. It could be your power door lock is wearing out on the passenger side. Replacing that is a trickier job as you have to go deeper into the door to replace it.
one last question, what is the order of sequence for the connectors on the window switch.
From the top I know it is brown then black, what color comes next, the FSM does not say and I am in a bind.
my 95 and 96 don't have screws on the aft end. i can see where they might go as there is a molded bracket on the frame but no screw. anybody have a pixie?