Tools You'll Need:
* Socket set (metric): Various sizes, likely including 10mm, 13mm, and possibly others.
* Wrench set (metric): For those stubborn bolts a ratchet can't reach.
* Screwdrivers: Phillips and flathead, various sizes.
* Pliers: Needle-nose and regular.
* Torx bits (if applicable): Some models might use Torx screws.
* Jack and jack stands: Essential for safety. Never work under a vehicle supported only by a jack.
* Wheel chocks: To prevent the vehicle from rolling.
* Shop rags or towels: To protect the door and vehicle's paint.
* Penetrating oil (PB Blaster or similar): To loosen rusted or stuck bolts.
* Door panel removal tool: Helps avoid scratching the panel. (Optional, but recommended)
* Repair manual: A MUST-HAVE for specific details and torque specs for your vehicle.
Procedure:
1. Disconnect the Battery: This prevents accidental shorts and electrical damage.
2. Prepare the Vehicle: Securely jack up the vehicle and place it on jack stands. Engage the parking brake and use wheel chocks.
3. Remove Interior Door Panel:
* Begin by removing the door handle bezel(s). These usually have screws or clips.
* Next, remove the armrest (if applicable). Look for screws or clips.
* Disconnect the window switch and power lock actuator connectors (if equipped).
* Carefully pry the door panel away from the door using a door panel removal tool or a flathead screwdriver (covered with tape to prevent scratches). Work your way around the perimeter, releasing clips. The panel is likely held on by multiple clips and screws.
4. Disconnect Window Regulator and Door Lock Mechanism:
* Once the door panel is removed, you'll see the window regulator, door lock mechanism, and other components.
* Disconnect the window regulator cable from the handle mechanism.
* Disconnect the door lock linkage.
* Disconnect any other electrical connectors attached to the door.
5. Remove the Door:
* Locate the hinges on the door; usually two or three hinges per door.
* Remove the hinge pins from the hinges. These pins often have a retaining clip or are held in place by a bolt. You might need to use a punch and hammer to tap the pin out.
* Carefully lower the door towards the ground. Have a helper to assist in supporting the weight to avoid damaging the door or yourself.
6. Install the New/Replacement Door:
* Reverse the removal process to install the replacement door. Line up the hinges and insert the hinge pins.
* Ensure the door is properly aligned before fully seating the pins.
* Reconnect the window regulator, door lock mechanism, and all electrical connectors.
* Reinstall the interior door panel.
7. Lower the Vehicle and Test: Lower the vehicle carefully, reconnect the battery, and test all door functions: window, lock, and handle operation.
Important Considerations:
* Rust: On a 1990 vehicle, bolts and hinges might be seized due to rust. Use penetrating oil liberally and allow it to soak for several hours or even overnight before attempting to remove fasteners.
* Safety: Always prioritize safety. Use jack stands, wheel chocks, and work in a well-lit area. Never work under a vehicle supported only by a jack.
* Wiring: Be extremely careful when disconnecting and reconnecting electrical components. Take pictures or make notes to help you remember how things go back together.
* Repair Manual: A repair manual specific to your vehicle will provide invaluable step-by-step instructions, diagrams, and torque specifications. This is the most crucial element for a successful repair.
This is a general overview. The specific steps may vary slightly depending on the exact model and options of your 1990 Dodge Caravan. Again, a repair manual is essential to avoid damage and ensure a proper repair. If you're not comfortable performing this task yourself, it's always best to consult a qualified mechanic.
