Tools you'll likely need:
* Screwdrivers: Phillips head and possibly flathead, depending on the screws.
* Panel removal tools: These plastic tools help prevent scratching the interior door panel. A flat, stiff putty knife can work in a pinch, but use extreme caution.
* Socket set (possibly): Some Tahoe models may use nuts and bolts instead of screws.
* New exterior door handle: Make sure you get the correct one for your year and model, and for the correct side (driver's or passenger's).
* Penetrating oil (optional): If screws are rusted or seized.
Steps:
1. Remove the Interior Door Panel: This is the most crucial and potentially tricky step. You'll need to carefully pry off the panel using your panel removal tools. Start at the edges, working your way around. There are usually clips and screws holding it in place. Look for screws around the armrest and possibly near the door handle. Some panels may have a release mechanism hidden behind the armrest. Refer to a repair manual to see exactly where these are located to avoid damage.
2. Disconnect the Interior Door Handle: The interior door handle mechanism is usually connected to the exterior handle mechanism. You'll need to carefully disconnect this linkage. This often involves disconnecting a rod or cable.
3. Access the Exterior Door Handle: Once the interior panel is removed, you should see the exterior door handle mechanism. You might need to remove a few more screws or bolts holding the handle mechanism in place.
4. Remove the Exterior Door Handle: Carefully remove the screws or bolts holding the exterior door handle to the door. Again, penetrating oil might be helpful if things are stuck.
5. Install the New Exterior Door Handle: Align the new door handle with the existing mounting holes and secure it with the screws or bolts you removed earlier.
6. Reconnect the Interior Door Handle: Reconnect the interior door handle linkage to the new exterior handle mechanism.
7. Reinstall the Interior Door Panel: Carefully reinstall the interior door panel, making sure all the clips are properly engaged.
8. Test the Door Handle: Test the new door handle to ensure it functions correctly.
Important Considerations:
* Repair Manual: A repair manual is highly recommended. It will provide detailed diagrams and instructions specific to your 1995 Chevy Tahoe.
* Patience: This is not a quick job. Take your time and be careful to avoid breaking any clips or damaging the door panel.
* Photos: Take pictures as you disassemble the door to help you remember how everything goes back together.
* Professional Help: If you're not comfortable working on your car yourself, it's always best to take it to a qualified mechanic.
Failing to properly remove the interior panel is the most common source of damage. Take your time and be gentle! If something seems wrong, stop and refer to the repair manual.
