1. Diagnose the Problem:
* Handle won't move: This could be a broken linkage, a seized mechanism, or a problem with the internal parts within the door.
* Handle moves but doesn't unlock/lock: The problem lies within the linkage connecting the handle to the locking mechanism.
* Handle is loose or broken: The handle itself might be cracked or the mounting screws are loose or stripped.
2. Common Repair Scenarios & Solutions:
* Broken Internal Linkage: This is the most common issue. You'll need to remove the interior door panel to access the linkage.
* Removal of Interior Door Panel: Consult a repair manual specific to your 1991 Chevy Blazer. This will show you how to remove the panel without damaging clips. Generally, this involves removing screws and carefully prying the panel away from the door. Be gentle to avoid breaking clips.
* Inspecting the Linkage: Once the panel is off, you'll see the linkage connecting the interior and exterior handles to the locking mechanism. Look for broken or bent parts.
* Repairing or Replacing the Linkage: If the linkage is simply bent, you might be able to straighten it carefully. However, if it's broken, you'll likely need to replace it. These parts are sometimes available at auto parts stores, junkyards, or online.
* Reassembly: Once the linkage is repaired or replaced, carefully reassemble everything, ensuring the linkage is properly connected.
* Seized Mechanism: Lubrication is key here. Use a penetrating lubricant (like PB Blaster or WD-40) liberally on the mechanism's moving parts. Work the handle back and forth gently to help distribute the lubricant. If it's still seized after several attempts, you may need to disassemble the mechanism (this is often more complex and may require specialized tools).
* Loose or Broken Handle:
* Loose Handle: Tighten the mounting screws. If the screw holes are stripped, you may need to use screw hole repair kits or replace the handle.
* Broken Handle: You'll need to replace the entire exterior door handle. These are usually available at auto parts stores.
3. Tools You Might Need:
* Screwdrivers (Phillips and flathead)
* Panel removal tools (plastic pry tools to avoid scratching the door panel)
* Penetrating lubricant
* Replacement parts (linkage, handle, screws)
* Repair manual (highly recommended)
4. Important Considerations:
* Repair Manual: A repair manual specific to your 1991 Chevy Blazer is invaluable. It will provide detailed instructions and diagrams for removing panels and accessing the door handle mechanism.
* Safety: Disconnect the negative battery terminal before working on any electrical components.
* Patience: Working on car door handles can be fiddly. Take your time and be methodical.
* Professional Help: If you're not comfortable working on your car, take it to a mechanic.
By carefully diagnosing the problem and following the appropriate steps, you should be able to repair your 1991 Chevy Blazer's exterior door handle. Remember to consult a repair manual for detailed instructions and diagrams specific to your vehicle.
