Here's a general outline. Specific details might vary slightly depending on trim level and any modifications to your truck. Consult a repair manual specific to your 1991 S-10 for detailed diagrams and instructions. A Haynes or Chilton manual would be very helpful.
1. Interior Door Panel Removal: Begin by removing the interior door panel. This usually involves removing screws around the armrest, door handle, and possibly under the panel itself. There are usually clips holding the panel in place as well. Carefully pry these loose with a plastic trim tool to avoid damage. Once the screws and clips are removed, the panel should pull off.
2. Disconnect Window Regulator and Door Lock Mechanisms: Once the interior panel is removed, you'll see the window regulator and door lock mechanisms. Disconnect the electrical connectors for these.
3. Disconnect Door Release Cable: Locate and disconnect the door release cable from the latch mechanism.
4. Remove the Door Handle: Remove the exterior door handle. This usually involves removing screws or bolts that are accessible after removing the interior panel.
5. Locate and Remove the Hinge Pins: The door is mounted on hinges with hinge pins. These pins are usually held in place by a retaining clip or cotter pin. Remove these securing mechanisms. You may need a punch or a small drift to gently tap out the hinge pins.
6. Lift the Door Off: Once the hinge pins are removed, carefully lift the door off its hinges. It may be heavy, so have a helper assist you if needed.
Reassembly is the reverse of this process. Remember to lubricate the hinge pins before reinstalling the door. This will help prevent squeaks and ensure smooth operation.
Important Notes:
* Take Pictures: Before you begin disassembly, take plenty of photos. This will help you remember how everything goes back together.
* Label Wires: If you disconnect any electrical connectors, label the wires to avoid confusion during reassembly.
* Patience: Be patient and methodical. Rushing the process can lead to damage or broken parts.
* Professional Help: If you are uncomfortable performing this task yourself, it is always best to seek the help of a qualified mechanic.
This is a general guide. A repair manual specific to your vehicle is strongly recommended to ensure you have the most accurate and safe procedure. Incorrect removal can damage your vehicle.
