Rear Interior Door Trim Panel/Removal

CAUTION:
DO NOT DISTURB THE ENERGY ABSORBING FOAM AT ANY TIME DURING THE PROCEDURE. IF ENERGY ABSORBING FOAM IS REMOVED FROM DOOR OR DOOR TRIM PANEL, IT MUST BE REPLACED WITH A NEW PART. IF OMITTED FROM THE DOOR OR DOOR TRIM PANEL, THE VEHICLE WILL NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS), SUBJECTING THE RETAILER TO POSSIBLE CIVIL PENALTIES FOR MAKING THE VEHICLE INOPERATIVE TO THE FMVSS, AND INCREASING THE RISK OF INJURY TO THE VEHICLE OCCUPANT.





1. Remove the rear door trim panel:

a. Remove fastener from center of inside door handle assembly.

b. If equipped, remove the power window switch from the door handle assembly.

c. If equipped, disconnect the power window electrical connection.

d. Slide door handle assembly forward while pulling outward from the trim panel. Using a thin screwdriver disengage lock and latch rod from retainers.

e. If equipped, remove power door lock rod.





f. On manual window vehicles, using a standard window handle tool, disengage manual window regulator handle clip and remove window handle.





g. Open access door cover at rear of door trim panel and remove door trim panel fastener.

h. Remove door trim panel fasteners at pull cup location.

i. Pull up on the door trim panel assembly to disengage the trim panel to door structure attaching hooks and remove the door trim panel.





2. Place the door trim panel (heat staked side up) on a work bench with a cloth type material to protect the panel's finish.

IMPORTANT:
Drill into the heat staked stud just enough to cause the stud material to separate from the substrate (door trim panel) material.





3. Using a 7 mm (9/32 in.) drill bit, drill out the round heat staked studs.





4. Remove the rectangle shaped heat stakes with a hand grinder (die grinder) using a 38 mm (1.25 in.) diameter grinding disk, or equivalent, by grinding the studs from the side.





5. Remove the old door insert from the door trim panel.

6. Remove any heat stake material that may be left in the door trim panel holes, or on the door trim panel substrate.