Door Assembly...the EASY way with Pictures

[randy500]

I have posted this new thread because the old one has a lot of comments and the pictures I added are on page 3, I wanted the pictures on page one. The old thread is still here....http://67-72chevytrucks.com/vboard/s...d.php?t=732400

Tool List
3/8 drive #2, #3 and $4 Philips screwdriver bits, available online from Snap-On, maybe harbor freight, Lowes, home depot.
Air or electric 3/8 drive impact, I like using my DeWalt cordless driver impact with a 3/8 drive adapter, lots of power and no hose to get in my way.
Combination square, remove the ruler portion and use the ruler to release window sweep clips. This works much better than a screwdriver since its thicker and wider, it also won’t go under the clip, it just pushes it up and as it pushes up it releases the clip.

Disassembly
1. Remove lower rear channel, 2 Philips head machine bolts under door panel, one Philips head machine screw in door jamb above latch.

2. Remove door lock, (makes clearance for the door latch)

3. Remove door latch with handle control and lock rod attached.

4. Remove window inner whiskers and outer rubber wipe, use the ruler portion of a combination, slide it along the lower window opening until you encounter the clip, lower it to get under the clip then push up to release the clip, continue from one end to the other until all are released, use your other hand to pull up on the whisker or rubber sweep to get it released.

5. Slide the window all the way back to the rear till it touches the door

6. Remove the wing window, 3 Philips head screws in the door frame and 2 Philips head machine screws under the door panel, use your impact so you don’t round them out. Tilt the wing window back, then start pulling it up until you’re in the middle of the door frame window opening, rotate the forward pointy part to the inside of the window opening (passenger compartment side) and extract the assembly. (if you extract it from the outer side there is less clearance.)

7. Slide the window forward an inch or so and roll the window up while supporting the upper glass until the window lower channel with the regulator rollers exit the door, then slide the window forward off the regulator rollers. The window should exit the door frame on the outer side.

8. Remove the window regulator.

Assembly
1. Install regulator

2. Roll up regulator while guiding rollers through window opening until the rollers are outside the window opening an inch or so.

3. Slide the glass on the rollers, outside the window opening from front to rear. Roll the window down all the way and slide glass to rear as far as it will go.

4. Install the wing window from inside the window opening (passenger compartment side) with wing window pointing towards passenger compartment. When lower channel is far enough in the door, turn the assembly 90 degrees and push if forward to seat in the opening.

5. Roll the window up while guiding it forward into the wing window run channel

6. Install door latch with lock rod and handle control attached as one unit.

7. Install door lock

8. Roll the window all the way up, install the window rear channel, just install the door jamb screw and this time and install it one revolution from finger tight, this allows it to dangle free but not too-free.

9. Roll the window all the way down and slide forward into front channel.

10. Slide the rear run channel weather-stripping down into the door feeding it into the lower rear channel. (You should mark the weather-strip upper length needed prior to doing this so you know when to stop feeding it down.) Ensure the weather-strip is fully seated in the rear channel especially at the very top of the channel.
The picture in post 21 below shows where to feed the rear run weatherstripping, if not fed down into the channel, the weatherstrip at the end will bind when the glass is rolled up, you would think the glass would push it in but it wont, it just binds, so ensure its fully seated at that location and where it begins to fit the rear door frame at the same location.

11. Install the lower rear channel remaining machine screws and tighten them all.

12. Install the inner and outer window sweeps.

Short cuts and why they don’t work and just cause frustration.
1. Not removing the door latch.
If you don’t do this there is not enough room to remove the wing window without forcing it out. If you remove the latch you have enough room to slide the window back far enough so that the wing window has clearance between the window and the welded door support which holds the inner and outer door skins together.

2. Not removing the door lock at all or before removing the door latch.
The door latch is difficult to remove or install with the lock in the way, just take it out. Pry the clip off with a long pry bar against the inner door structure, then retrieve it with flashlight and magnet, grease the clip before installing it will help it slide in.

3. Removing or installing the latch with the handle control and lock rod attached.
The clips for the rods are difficult to maneuver and install or release inside the door, lay it out on the bench and install as one unit to make it easier.

4. Not removing the window sweeps.
You need them removed to get the window lower channel and regulator rollers to clear the window opening to remove the window from the regulator. Removing them also creates clearance for the wing window lower support to clear the opening.

5. Changing the regulator without full door disassembly
Don’t even try to shortcut the process by thinking you can change this without full door disassembly, you will regret it. It is possible but it’s hard to get the 3 rollers in the channels and the wing window interferes with the regulator, its especially bad if it’s a ’72 regulator with the longer shaft, you just cut up your arms trying to save a few steps, its not worth it.

6. The door frame tilts inward therefore I should remove the wing window from the outside of the window opening.
Sound theory but the clearance problem is with the lower screw bracket on the wing window inside of the door, when you do it this way that part has less room inside the door as the inner door has more clearance towards the outer door skin since it curves outward from the door frame.
The clearance to rotate the wing window is increased if you install the wing window from the passenger compartment side of the door frame opening.

Picture of tools and door hardware that each tool fits.