Here's a general outline. Specific steps and details might vary slightly depending on your exact trim level and any aftermarket modifications. Consult a repair manual specific to your 2004 Chevy Avalanche for precise instructions and diagrams. A Haynes or Chilton manual is a good investment for this kind of work.
1. Preparation:
* Gather Tools: You'll need various tools, including screwdrivers (Phillips and possibly flathead), sockets (various sizes), wrenches, pliers, and possibly a door panel removal tool kit to avoid damaging clips.
* Disconnect the Battery: This is crucial for safety.
* Gather Parts (Optional): Have replacement parts (like screws or clips) on hand. You're bound to break some clips.
2. Interior Door Panel Removal:
* Remove Interior Door Handle: Typically involves removing screws or clips that hold it in place.
* Remove Door Panel: Start by removing the screws around the edges of the door panel. Many panels use plastic clips, so gently pry them loose using a trim removal tool or a flathead screwdriver (covered in cloth to prevent scratching) to avoid damage. Work your way around the perimeter. There may be connectors for the power window switch, door lock, and courtesy lights. Carefully disconnect these connectors.
* Unplug Electrical Connectors: Carefully unplug the connectors from the power window switch, door lock, and interior courtesy light.
3. Exterior Door Removal:
* Disconnect Window Regulator Cable (If Applicable): Disconnect the window regulator cable from the door.
* Disconnect External Door Handle Linkage: Disconnect the rod(s) that connect the exterior door handle to the door latch mechanism.
* Remove Door Weatherstripping: Carefully remove the weatherstripping around the door frame, usually by peeling it back. Avoid tearing it.
* Remove Door Latch Mechanism: This step often involves removing screws or bolts holding the latch in place.
* Remove Hinge Pins: Locate the hinge pins that connect the door to the vehicle body. These pins are typically held in place by a retaining clip or cotter pin. Remove these retaining mechanisms. Use a punch or drift to tap the hinge pins out. The pins will likely fall out once you remove the retaining clip.
* Lower the Door: Gently lower the door to the ground, supporting its weight to prevent damage.
4. Reassembly:
Reassembly is the reverse of the removal process. Make sure all electrical connectors are securely plugged in and the hinge pins are properly seated.
Important Considerations:
* Safety First: Work in a well-lit and safe area. Have someone help you if you need assistance supporting the door.
* Take Pictures: Take pictures of each step as you disassemble the door. This will be invaluable during reassembly.
* Repair Manual: Seriously, use a repair manual. It will have specific diagrams and torque specifications. Failing to follow these could lead to damage or injury.
* Broken Clips: Expect to break some plastic clips. Replacement clips are readily available at auto parts stores.
This is a simplified overview. The actual process might be more complex. Always refer to a repair manual for your specific vehicle before attempting this repair. If you are not comfortable performing this task yourself, it is best to take your vehicle to a qualified mechanic.
