I was searching all over but finding nothing - does anybody know of a thread or instructions on removing and replacing a passenger door (not fuel door, nor a door panel, which is where all the searching leads). Is it very difficult to align the gaps, are shims or any special tools required?

Thanks in advance,
Andy

 

I have replaced doors on other cars without any problems. It was pretty easy, but I don't know if I would want to try it on my C5. I am sure there are guys here that have done it.

 

Yes, strange isn't it. There's a billion repeating threads on removing the trim panel from inside the door (very easy), but no threads on removing and replacing an actual door. Oh well, guess I'll just go wrenching away and see where I get to. If I find some tricks I'll post.

There was this thread, but it went unanswered...
https://www.corvetteforum.com/forums...ht=remove+door

 

If the new door is exactly the same as the old door, it should be easy to fit it. If I had done It I could help you. Good luck.

 

So you'll have two choices here;

1) Replacing the door with the hinges on the body will require less removal. However, you will for sure need a helper, as you'll need someone (or something) to hold the door in position while the hinges are loosened from the body. It'll also require some work to position properly, even if markings are made.

2) Replacing the door at the hinge will be a bit easier for mounting and adjusting, but you will have to remove the fender to accomplish this. It'll be a bit easier because the door can be flushed against the body while you make adjustments. It probably won't require as much adjustments.

Either way will work. You simply remove the bolts off the hinge from whatever you decide to do; body or the door itself. I would use a chalk marker pen to also mark either the position of the hinge or the door against the hinge before you begin removal.

The door has a multi-prong connector that you will need to disconnect. You pull the accordion sleeve back and you'll see it. While you have it apart check the connectors and make sure the wiring is well seated on each side.

If the door you have obtained is a complete unit after the door is installed you will likely have to adjust the window deflection point. This is done by the adjustment screw that is "behind" where the door reflector is. It adjusts the deflection either further into the car or outwards.

 

Go for it, I can't see it being too hard. Just be careful with the many pin connector in the door's boot.
Putting these Lambo doors on was a bitch, though.

 

Cover as much as you can with masking tape to prevent any chips. Go slow, be careful and when you do need help, don't try to do it alone.