1. Preparation:
* Disconnect the battery's negative terminal. This prevents accidental short circuits.
* Gather tools: You'll need a trim panel removal tool (plastic pry tools are best to avoid scratching), Phillips head screwdriver, possibly a Torx screwdriver (check your door panel), and pliers.
2. Removing the Interior Door Panel:
* Window down: Lower the window all the way. This gives you more room to work and prevents accidental damage to the window regulator.
* Remove the door handle bezel: This is usually held on by screws (often hidden under small caps). Carefully pry it loose with your trim removal tool.
* Remove the door panel screws: These are usually located around the perimeter of the panel. Look closely – some might be hidden under the armrest or other components.
* Disconnect the electrical connectors: These are usually for the power window switch, door lock, and courtesy light. Gently disconnect them. Take a photo or make a note of how they connect for reassembly.
* Remove the door panel: Gently pry the panel away from the door. There are usually plastic clips holding it in place. Start at the bottom, working your way around. Be careful not to break the clips.
* Door panel release lever: Some Tahoes have a lever or latch at the bottom near the panel edge; you might have to release that to remove the panel.
3. Accessing the Door Handle Mechanism:
* Locate the broken cable: With the door panel removed, you should now see the inner door handle mechanism. The cable is usually attached to a rod or lever.
* Repair or replacement: The repair might involve reattaching the cable, replacing the cable itself, or potentially replacing the entire door handle mechanism. You might need to remove some additional screws or clips to access the specific parts. A repair manual will guide you on this.
4. Reassembly:
* Reverse the removal process: Carefully reattach the handle mechanism, reconnect the electrical connectors, and reattach the door panel. Ensure the clips are correctly engaged.
* Test the handle: Before completely reassembling, check that the handle works properly.
* Reconnect the battery.
Important Notes:
* Repair Manual: A factory or Haynes repair manual for your specific 1996 Chevy Tahoe is invaluable. It will provide detailed pictures and instructions.
* Patience: This process can be time-consuming and requires patience.
* Take pictures: Take photos of each step during disassembly to assist you during reassembly.
* Plastic pry tools: Using the wrong tools can damage your door panel.
If you're uncomfortable performing this repair yourself, it's best to take your Tahoe to a qualified mechanic. Replacing a door handle is generally not a highly complex job but is fiddly.
