Tools You'll Likely Need:
* Screwdrivers: Phillips head and flathead, various sizes.
* Sockets and Wrenches: Metric, various sizes.
* Panel Removal Tools: Plastic pry tools to avoid scratching the door panel.
* Torx Bits (possibly): Some GM vehicles of this era used Torx screws.
* Electrical connector removal tool (optional but helpful): Makes disconnecting electrical connectors easier and safer.
* Gloves: To protect your hands.
* Shop rags: To keep things clean and prevent scratching.
* A repair manual: Invaluable for diagrams and torque specs.
Disassembly Steps:
1. Disconnect the Battery: This is crucial to prevent accidental shorts and damage to electrical components.
2. Remove the Interior Door Panel:
* Window Switch and Crank Handle: Carefully remove any screws securing the window switch panel and the door handle. These are usually located around the switch panel and handle itself.
* Door Panel Retainers: There will be plastic clips and possibly screws holding the door panel in place. Start by carefully prying around the edges of the door panel using plastic trim tools. Work your way around the perimeter, releasing the clips gently. Be mindful of the door panel itself, as these clips can break easily. There might be some hidden screws behind covers (e.g., armrest or door pull).
* Disconnect Electrical Connectors: Once the panel is loose, disconnect the electrical connectors for the power window switch, door lock, and possibly speakers. Use a connector removal tool if you have one to avoid damaging the connectors.
3. Remove the Door Handle Mechanism (if necessary): If you're replacing the handle, or need access to internal mechanisms, there will be screws and clips securing the inside door handle assembly. Consult your repair manual for the precise procedure.
4. Remove the Window Regulator and Motor (if necessary): This usually involves removing additional screws and clips holding the regulator and motor assembly to the door. Again, your repair manual will provide precise instructions. Be careful not to damage the window regulator cable.
5. Remove the Door Lock Mechanism (if necessary): The lock mechanism is usually secured with several screws and possibly retaining clips. Access will depend on the specific design. Your repair manual will guide you.
6. Remove the Exterior Door Handle (if necessary): This often involves accessing screws from inside the door after removing the interior panel.
Important Considerations:
* Take Pictures: Before disconnecting anything, take detailed pictures so you can remember how everything goes back together.
* Label Wires: If you disconnect any electrical connectors, label them clearly to avoid confusion during reassembly.
* Gently Pry: Avoid using excessive force when prying. Plastic trim tools are essential to prevent damage.
* Repair Manual: This is crucial. Pictures and specific instructions from a repair manual are invaluable.
This is a complex process, and variations exist depending on your specific Roadmaster's configuration. Always consult a repair manual for your specific year and model. If you're uncomfortable performing this task yourself, consider taking it to a professional mechanic.
