1. Identify the Damage:
* Dents: Minor dents might be repairable with a dent puller kit (available at auto parts stores). Larger or more complex dents might require professional PDR (Paintless Dent Repair) or body filler work.
* Scratches: Minor scratches can be buffed out with rubbing compound and polishing compound. Deeper scratches may require touch-up paint and clear coat.
* Rust: Rust is a serious issue. You'll need to remove all the rust, treat the affected area with a rust converter, apply a primer, and then repaint. Extensive rust might require panel replacement.
* Broken Window: Replace the window with a new one from an auto parts store. This often involves removing the interior door panel to access the window mechanism.
* Broken Door Handle or Latch: These are usually replaceable parts. You may need to remove the interior door panel to access them.
* Bent Door Frame: This is a serious issue and likely requires professional repair or even frame replacement.
* Broken Hinges: Replace the broken hinges. This will require removing the door.
2. Common Repair Steps (General):
* Gather Tools: You'll likely need various tools depending on the type of repair, including screwdrivers (Phillips and flathead), wrenches, sockets, pliers, putty knife, sandpaper, primer, paint, clear coat, and possibly a dent puller kit.
* Remove the Interior Door Panel: This usually involves removing screws around the edges of the panel. Consult a repair manual for your specific Astro van model for precise instructions. This gives access to the door mechanisms, window regulators, and other components.
* Assess the Damage More Thoroughly: Once the panel is off, you'll have a better view of the extent of the damage.
* Repair the Damage: This step varies greatly based on the type of damage (see section 1).
* Reinstall the Interior Door Panel: Carefully reattach the panel, making sure all screws are securely fastened.
* Test the Door: Make sure the door opens and closes properly, the window operates correctly, and the latches work as intended.
3. Resources:
* Repair Manuals: A Haynes or Chilton repair manual for your 1998 Chevrolet Astro van is invaluable. These manuals provide detailed instructions and diagrams.
* Online Forums: Search online forums specific to Chevrolet Astro vans (e.g., on forums like AstroSafari.com). Other owners may have faced similar problems and can offer advice or solutions.
* YouTube: Search YouTube for videos showing repairs on similar vehicles. This can be helpful in visualizing the process.
* Auto Parts Stores: Auto parts stores (like AutoZone, Advance Auto Parts, etc.) can provide replacement parts and advice.
Important Notes:
* Safety First: Always disconnect the battery's negative terminal before working on any electrical components.
* Professional Help: If the damage is extensive or you're uncomfortable with any aspect of the repair, take your van to a professional auto body shop.
Without knowing the specific damage to your Astro van's side door, this is the most comprehensive advice I can offer. Please provide more detail about the damage, and I'll do my best to give more specific guidance.
