1. Diagnose the Problem:
* Identify the specific issue: Is the handle broken? Is the latch mechanism itself malfunctioning (won't engage or disengage)? Is the linkage broken? Is the actuator (the motor part if power locks are present) failing? A visual inspection is crucial. Try operating the inside and outside handles to determine the point of failure. Try using the power locks (if equipped) to see if the actuator is working.
* Check for obvious damage: Look for broken plastic parts, bent metal components, or anything obviously out of place.
2. Gather Supplies and Tools:
* Replacement parts: You'll likely need to replace at least part of the latch mechanism. Finding the correct parts for a 1992 Astro van might require going to a junkyard, a specialized auto parts store (like a NAPA Auto Parts that can search by VIN), or an online retailer specializing in classic car parts. Having the part number (from a parts diagram) will be invaluable.
* Tools: You'll probably need a screwdriver set (Phillips and flathead), possibly pliers, possibly sockets and wrenches (depending on the complexity of the repair), and potentially a panel removal tool to avoid scratching the interior trim.
3. Accessing the Latch Mechanism:
* Interior Panel Removal: You'll need to remove the interior door panel to access the latch mechanism. This usually involves removing screws around the edges of the panel and possibly disconnecting some electrical connectors (power locks, window switches). Consult a repair manual for your specific year and model for detailed instructions. Online videos showing interior panel removal for similar-year vehicles can also be helpful. Be gentle to avoid breaking any plastic clips.
4. Repair or Replacement:
* Simple repairs: If it's just a broken plastic piece on the handle, you might be able to superglue it, but this is a temporary fix at best. If the linkage is simply disconnected, reconnecting it is a straightforward repair.
* Latch mechanism replacement: This is the most likely scenario. Once you have the interior panel off, you should see the latch mechanism. Take pictures before disassembling anything to aid in reassembly. Carefully disconnect the linkage rods and any electrical connectors. Compare the old and new parts carefully during installation.
* Actuator replacement (if power locks are involved): If the power locks aren't working, the actuator might be the culprit. This often involves removing the door panel and accessing the actuator. Again, comparing the old and new actuator before installation is essential.
5. Reassembly:
* After installing the new parts, carefully reverse the disassembly process. Make sure all the linkage rods are correctly connected and that the interior door panel is securely fastened.
Important Considerations:
* Repair Manual: A repair manual specific to your 1992 Chevrolet Astro van is highly recommended. It will provide detailed diagrams and instructions. You can often find these online (PDF downloads) or in auto parts stores.
* Safety: Disconnect the negative battery terminal before working on any electrical components.
* Complexity: If you're not comfortable working on car mechanics, it's best to take your Astro van to a qualified mechanic. Replacing the latch mechanism can be moderately difficult, depending on the model and the specific failure.
* Part Availability: Finding parts for a 1992 Astro van might be challenging. Junkyards are a good option for used parts.
By carefully diagnosing the problem and following these steps, you can hopefully repair your broken exterior rear door latch. Remember, if you're unsure about any step, seek professional help.
