GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Express 🢒 Body 🢒 Doors 🢒 Front Side Door Replacement

Tools Required

    • J 41226 Door Hinge Pin Drillout Kit
    • J 41226-50 Door Hinge Pin Adapter Kit

Removal Procedure
  1. Remove the side front door trim panel. Refer to Front Side Door Trim Panel Replacement .
  2. Remove the hinged side window or the stationary side window. Refer to Body Side Window Replacement or Body Side Window Replacement in Stationary Windows.
  3. Remove the side front door inside handle. Refer to Door Inside Handle Replacement .
  4. Remove the side front door outside handle. Refer to Door Outside Handle Replacement .
  5. Remove the weatherstrips, if needed. Refer to Side Front Door Weatherstrip Replacement or Intermediate Side Door Window Weatherstrip Replacement .
  6. Remove the side door upper and lower door wedges from the door. Refer to Sliding Rear Side Door Locator and Door Side Wedge Replacement .
  7. Remove the lock rod retainers from the side front door.

    8. Rotate the retainers 90 degrees and pull the retainers out.

  8. Remove the lock assembly from the door. Refer to Front Side Door Lock Replacement .
  9. Remove the side front door wiring harness. Refer to Sliding Door Wiring Harness Replacement .
  10. Remove the side front door check strap. Refer to Front Side Door Check Strap Replacement .
  11. Remove the side front door check strap seal. Refer to Front Side Door Check Strap Seal Replacement .

    12. Object Number: 334006 Size: SH
  12. Remove the side front door hinge pins using the J 41226 and the J 41226-50 .
  13. Remove the side front door from the vehicle with an assistant.

Installation Procedure

    Object Number: 334006 Size: SH
  1. Install the side front door to the vehicle with an assistant.
  2. Install the side front door hinge pins using the J 41226 and the J 41226-50 .
  3. Install the side front door check strap seal. Refer to Front Side Door Check Strap Seal Replacement .
  4. Install the side front door check strap. Refer to Front Side Door Check Strap Replacement .
  5. Install the side front door wiring harness. Refer to Sliding Door Wiring Harness Replacement .
  6. Install the lock assembly to the door. Refer to Front Side Door Lock Replacement .
  7. Install the lock rod retainers by inserting the retainers into the side front door.

    8. Rotate the retainers 90 degrees.

  8. Install the side door upper and lower door wedges to the door. Refer to Sliding Rear Side Door Locator and Door Side Wedge Replacement .
  9. Install the weatherstrips, if needed. Refer to Side Front Door Weatherstrip Replacement or Intermediate Side Door Window Weatherstrip Replacement .
  10. Install the side front door outside handle. Refer to Door Outside Handle Replacement .
  11. Install the side front door inside handle. Refer to Door Inside Handle Replacement .
  12. Install the hinged side window or the stationary side window. Refer to Body Side Window Replacement or Body Side Window Replacement in Stationary Windows.
  13. Install the side front door trim panel. Refer to Front Side Door Trim Panel Replacement .