GM Astro/Safari 1985-1996 Repair Guide

Door Locks

Print

REMOVAL & INSTALLATION



Front Door Manual Locks
OUTSIDE HANDLE AND LOCK CYLINDER

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the outside handle and lock cylinder assembly-front door

  1. Refer to the Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. Remove the outside handle-to-door nuts.
  4.  

Removing the soft plug at the edge of the door may provide additional room to access the bottom door handle nut.

  1. Remove the outside handle-to-lock rod and the handle from the door.
  2.  
  3. Remove the lock rod from the lock cylinder, then the lock cylinder retainer, the gasket and the lock cylinder from the door.
  4.  

To install:
  1. Install the lock rod to the lock cylinder, then the lock cylinder retainer, the gasket and the lock cylinder to the door.
  2.  
  3. Install the outside handle-to-lock rod and the handle to the door.
  4.  
  5. Install the outside handle-to-door nuts.
  6.  
  7. Install the door panel.
  8.  

LOCK ASSEMBLY

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Lock cylinder assembly mounting and related components-front door

  1. Refer to the Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. Remove the outside handle-to-lock assembly rod.
  4.  
  5. Remove the lock cylinder-to-lock assembly rod.
  6.  
  7. Remove the inside handle-to-lock assembly rod.
  8.  
  9. Remove the inside lock-to-lock assembly rod.
  10.  
  11. Remove the lock assembly-to-door screws and the lock assembly from door.
  12.  
  13. Installation is the reverse of the removal.
  14.  

INSIDE HANDLE

See Figure 3



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the inside door handle mounting-front door

The following procedure requires the use of a3/16in. (5mm) drill bit,1/4in. x1/2in. (6mm x 13mm) pop rivets and a pop rivet gun.

  1. Refer to the Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. Remove the inside handle-to-lock rod.
  4.  
  5. Using a 3 / 16 in. (5mm) bit, drill out the inside handle-to-door rivets, the remove the inside handle from the door.
  6.  

To install

  1. Use 1 / 4 in. x 1 / 2 in. (6mm x 13mm) pop rivets and a pop rivet gun to install the inside handle to the door. Install the trim panel and check operation.
  2.  

Front Door With Power Locks

See Figure 4



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of typical Astro and Safari power door lock components

REMOTE LOCK LEVER

The following procedure requires the use of a3/16in. (5mm) drill bit,1/4in. x1/2in. (6mm x 13mm) pop rivets and a pop rivet gun.

  1. Refer to the Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. Remove the power door lock motor to remove the lever rod.
  4.  
  5. Remove the remote lever-to-lock assembly rod.
  6.  
  7. Remove the remote lever-to-inside lock lever rod.
  8.  
  9. Using a 3 / 16 in. (5mm) bit, drill out the inside handle-to-door rivets, the remove the handle from the door.
  10.  

To install

  1. Use 1 / 4 in. x 1 / 2 in. (6mm x 13mm) pop rivets and a pop rivet gun to install the inside handle to the door.
  2.  
  3. Connect the remote lever-to-lock lever rod.
  4.  

POWER DOOR LOCK MOTOR
  1. Refer to the Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. Remove the power door lock motor to remove the lever rod.
  4.  
  5. Disconnect the electrical connector from the power door lock motor.
  6.  
  7. Remove the motor-to-door bolts and the motor from the door.
  8.  
  9. To install , position the motor to the door and install the mounting bolts. Reconnect the electrical connector and install the door trim panel.
  10.  

Sliding Door
LOCK ASSEMBLY

See Figure 5



Click image to see an enlarged view

Fig. Fig. 5: Lock assembly components-sliding door

  1. Refer to the Sliding Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. To remove the upper control-to-lock rods, perform the following procedures:
    1. Using a small prybar, pry the anchor clip out of the hole and push the clip away from the lever.
    2.  
    3. Pull the rod and clip away from the lever.
    4.  

  4.  
  5. To remove the remote control-to-locks rods from the remote control, perform the following procedures:
    1. Using a small prybar, pry the anchor clip out of the hole and push the clip away from the lever.
    2.  
    3. Pull the rod and clip away from the lever.
    4.  

  6.  
  7. Remove the lock screws and the lock from the door.
  8.  
  9. To install , position the lock and screws to the door. Connect the clips to the levers and check operation. Install the door trim panel.
  10.  

POWER DOOR LOCK MOTOR

See Figure 6



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of the power door lock motor assembly mounting-sliding door

The following procedure requires the use of1/4in. x1/2in. (6mm x 13mm) pop rivets and a pop rivet gun.

  1. Refer to the Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. Disconnect the negative battery cable from the battery.
  4.  
  5. Refer to the Sliding Door Panel, Removal and Installation procedures in this section and remove the door panel.
  6.  
  7. Disconnect the electrical wiring harness from the power door lock motor.
  8.  
  9. Using a 3 / 16 in. (5mm) bit, drill out the door lock motor-to-door rivets, then remove the motor from the door.
  10.  

To install

  1. Use 1 / 4 in. x 1 / 2 in. (6mm x 13mm) pop rivets and a pop rivet gun to install the inside handle to the door.
  2.  
  3. Install new rivets or bolts to the power door lock motor-to-door.
  4.  
  5. Connect the electrical wiring harness.
  6.  
  7. Refer to the Sliding Door Panel, Removal and Installation procedures in this section and install the door panel.
  8.  
  9. Connect the negative battery cable to the battery and check operation.
  10.  

Rear Door With Manual Locks
OUTSIDE HANDLE AND LOCK CYLINDER
  1. Refer to the Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. Remove the control rod from the outside handle by prying the clip anchor out of the hole and pushing the clip away from the lever. Then pull the rod and the clip away from the lever.
  4.  
  5. Remove the outside handle-to-lock nuts and remove the rod and the handle from the door.
  6.  
  7. Remove the license plate housing bolts, and the license plate housing.
  8.  
  9. Remove the door lock shield.
  10.  
  11. Remove the lock control rod from the lock cylinder by prying the clip anchor out of the hole and pushing the clip away from the lever. Then pull the rod and the clip away from the lever.
  12.  
  13. Remove the lock cylinder retainer, and the lock cylinder from the door.
  14.  

To install:
  1. Install the lock cylinder retainer, and the lock cylinder to the door.
  2.  
  3. Install the lock control rod to the lock cylinder.
  4.  
  5. Install the door lock shield.
  6.  
  7. Install the license plate housing assembly and bolts.
  8.  
  9. Install the outside handle-to-lock nuts and handle.
  10.  
  11. Install the control rod to the outside handle.
  12.  
  13. Refer to the Door Panel, Removal and Installation procedures in this section and install the door panel.
  14.  

LOCK ASSEMBLY

See Figure 7



Click image to see an enlarged view

Fig. Fig. 7: Rear door lock cylinder removal

  1. Refer to the Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. Remove the outside handle-to-lock assembly rod.
  4.  
  5. Remove the lock cylinder-to-lock assembly rod.
  6.  
  7. Remove the inside handle-to-lock assembly rod.
  8.  
  9. Remove the inside lock-to-lock assembly rod.
  10.  
  11. Remove the lock assembly-to-door screws and the lock assembly from door.
  12.  
  13. Installation is the reverse of the removal.
  14.  

UPPER AND LOWER LATCH REPLACEMENT

See Figure 8



Click image to see an enlarged view

Fig. Fig. 8: Upper and lower door latches

  1. Refer to the Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. Remove the control rods from the remote control by prying the clip anchor out of the hole and pushing the clip away from the lever. Then pull the rod and the clip away from the lever.
  4.  
  5. Remove the upper latch screws.
  6.  
  7. Remove the upper latch insulator cover.
  8.  
  9. Pry the plastic nails holding the weatherstrip away from the door and remove the weatherstrip from around the latch area.
  10.  
  11. Remove the door latch insulator.
  12.  
  13. Remove the upper latch and rod from the door.
  14.  
  15. Remove the lower latch screws.
  16.  
  17. Remove the lower latch reinforcement plate.
  18.  
  19. Remove the lower latch and rod from the door.
  20.  

To install:
  1. Install the lower latch and rod to the door.
  2.  
  3. Install the lower latch reinforcement plate.
  4.  
  5. Install the lower latch screws.
  6.  
  7. Install the upper latch and rod to the door.
  8.  
  9. Install the door latch insulator.
  10.  
  11. Install the weatherstrip to the latch area.
  12.  
  13. Install the upper latch insulator cover.
  14.  
  15. Install the upper latch screws.
  16.  
  17. Install the control rods to the remote control.
  18.  
  19. Refer to the Door Panel, Removal and Installation procedures in this section and install the door trim panel.
  20.  

Rear Door With Power Locks
REMOTE LOCK LEVER
  1. Refer to the Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. Disconnect the negative battery cable and remove the actuator to lever rod.
  4.  
  5. Using a 3 / 16 in. (5mm) bit, drill out the the head of the actuator-to-door rivets.
  6.  
  7. Remove the actuator from the door.
  8.  
  9. To install , use 1 / 4 in. diameter bolt ( 1 / 2 in. long) with a spring washer and nut to attach the actuator to the door. Connect the lever rod to the actuator. Check operation, then install the door trim panel.
  10.  

POWER LOCK ACTUATOR

See Figure 9



Click image to see an enlarged view

Fig. Fig. 9: Power lock actuator and related components

  1. Refer to the Door Panel, Removal and Installation procedures in this section and remove the door panel.
  2.  
  3. Remove the power door lock actuator to remove the lever rod.
  4.  
  5. Disconnect the electrical connector from the power door lock actuator.
  6.  
  7. Remove the actuator-to-door bolts and the actuator from the door.
  8.  
  9. To install position the actuator to the door and install the bolts. Connect the electrical connector and lever rod. Check operation, then install the door trim panel.
  10.  

 
label.common.footer.alt.autozoneLogo