GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Chevy C Cab/Chassis HD (GMT 400) 🢒 Body 🢒 Doors 🢒 Front Side Door Outside Handle Replacement

Removal Procedure
  1. Remove the trim panel. Refer to Upper Extension Trim Panel Replacement .
  2. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .
  3. Remove the inner mounting panel assembly. Refer to Front Door Module Replacement .

    4. Object Number: 277774 Size: SH
  4. Remove the outside handle rod from the rod clip.

    5. Object Number: 277776 Size: SH
  5. Remove the lock cylinder rod from the rod clip.
  6. Remove the outside handle mounting screws.
  7. Remove the door lock cylinder from the outside handle housing. In order to repair a binding lock cylinder, refer to Lock Cylinder Binding .
  8. Remove the handle.

Installation Procedure

    Object Number: 277776 Size: SH
  1. Install the handle to the vehicle.
  2. If the lock cylinder is a replacement, apply a coating of GM P/N 12345120 (Canadian P/N 726548) or a similar lubricant to the inside of the lock case and the cylinder keyway.
  3. Install the door lock cylinder to the outside handle housing. In order to code a new lock cylinder, refer to Key and Lock Cylinder Coding in General Information.

    4. Object Number: 277774 Size: SH
  4. Install the lock cylinder rod to the lock cylinder clip.
  5. Install the handle rod to the handle assembly clip.

    6. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6. Install the outside handle mounting bolts.

    7. Tighten
    Tighten the bolts to 4 N·m (35 lb in).

  7. Install the inner mounting panel assembly. Refer to Front Door Module Replacement .
  8. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
  9. Install the trim panel. Refer to Upper Extension Trim Panel Replacement .