As many of these trucks that are out there it's inevitable that things will break. Most common is the driver's side door handle, but we also carry a full lineup of outer door handles and door handle kits for Chevrolet and GMC Trucks and SUV's. Whether someone tried to break in, it was cold outside and it snapped, or it was just plain wore out over the years, you've probably ran across one at one time or another. Point is it has to be replaced, and taking it to the dealer will run about anywhere from $80-$100 plus parts. Or option #2 replace it yourself one evening and keep that cash in your pocket.
One of my fellow co-workers had a truck that someone needed to get into "without a key" so we swapped it out instead of taking it to a dealership. This particular truck is a 93 model. 88-98 outer door handles are the same so the only difference in replacement procedure would be the removal of the door panels, everything else should be the same.
First step was to take things apart. We started by removing the door panel. First step is to gently separate the inside door lock/handle bezel from the door panel. These are held into place with spring clips that slide into the door shell. Once it is loose there is a tab located at the rear that hold it in as well, slide it forward and it will come loose.
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Now all that is holding the bezel in place should be the power window/door switches "if so equipped". To release these, depress the 2 tabs located at the top and bottom rear of the switch. Once these are depressed you can use a common screwdriver to unplug them from the wiring harness.
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Once the plugs are out, there is a retainer located at the base of the individual harness. Depress this clip to release and slide the harness up and out of the bezel.
Once those are clear you can use a Phillips head screwdriver to take out the 2 screws holding the arm rest pad onto the door.
After that is loose, you need to use the door panel removal tool to pop the door panel clips loose from the door. These are very easy to break so it might not hurt to get some extra for replacements! When the clips are loose slide the door panel upward to release the top section of the panel.
Now that the door panel is out of the way, take a 7mm socket "note there is also one 10mm bolt" and take off all the retaining screws holding the center panel to the door.
Pull back the access panel carefully because the window regulator is attached to this and the window will slide down with the access panel. I used a jack to hold it in place while I worked but if you have a buddy hanging around that will work too.
Once the access panel is moved you can see the door handle. There are two 10mm bolts that hold it on the door shell. After removing these bolts the handle will be loose in the door but not ready to take out yet.
The door lock rod and latch rod are still attached to the handle. On the door edge you can see 3 torx headed bolts. Remove these to loosen the latch mechanism.
Once that is loose, go to the front side of the door and insert the door lock key. Turn it like you would while unlocking the door and it will move so that the bottom of the handle can come loose from the door.
With the bottom pulled out the top should be able to be pushed down to clear the door. With the handle hanging outside the door the 2 rods should be accessible to remove the retaining clips. To remove these you need to use a small pick/screwdriver to pry up the retaining tab and then slide the clip forward. With the clip slid forward the rods will slide out of the hole.
Now that the door handle is loose, you need to swap your lock cylinder over to the new door handle. On the back of the cylinder is a clip that holds the rod bracket to the cylinder. Once again there is a small tab that prevents this from coming loose. Pry that little tab up and the clip will slide back. With the clip out of the way the bracket will come off the same way. Once the bracket is off the cylinder will be able to slide out. Switch it to the new handle and reinstall the bracket and retainer clip.
Now it's time to put everything back together again. Reinstall the door lock and latch rods into their retainer clips. NOTE: if you bend the tabs on the clips back down it will keep them from moving when you are trying to reinstall the rods. When you slide them into place you should hear a slight click which lets you know they are engaged properly. With those installed you can put the door handle back in just like you took it out and bolt it up.
Next you want to reinstall the door latch and make sure the latch rod is still engaged to the latch. "To do this pull up on the door handle like you would when opening the door. If you can't hear the latch moving, the rod isn't engaged properly. You have to pull it all back loose and reinstall the rod in its retainer hold that is built into the latch." Once the handle and lock mechanisms are operating like they should, you need to go over everything to make sure all is functional and all fasteners are tight.
Next you need to reinstall the access panel back onto the door. An extra hand would prove useful here so you could install all the screws while it was being held in place. Once all those are tight, make sure all door panel clips are in and hang the door panel back on the door.
With the panel hanging, line up the door panel clips with the holes and press them into place. Reinstall the arm rest pad and tighten the retaining screws.
Now it's time to put the switches back in. Slide the wiring harness down into the retainer and make sure the latch catches on the bottom to hold it in place. The switches just plug into their corresponding holes. Now all that is left to do is reinstall the door handle bezel. Place the rear tab into the slot under the armrest pad, line up the other retainer tabs with their holes and press into place.
There you go, you're finished! And all it took was a little elbow grease and a little time to save you some cash.