How to Repair a 2002 Silverado's Door Window Regulator

As its own model, the Silverado debuted in the 1999 model year, but the name dates back to its introduction as the top trim level on Chevy pickups in 1975. The 2002 Silverados base trim level came standard with a 200-horsepower, 4.3-liter Vortec V-6 engine and a five-speed transmission. Also standard on the base level 2002 Silverado are manual windows. Just like power windows, these archaic devices use a regulator to raise and lower the window, but your arm acts as the motor. Replacing the regulator on the base level 2002 Silverado requires partially disassembling the door panel, so use caution not to break any of the plastic components in the process.

Instructions

Open the door with the failed window regulator and leave it open. Remove the inside door handle bezel -- the trim piece surrounding the inside door handle -- by prying around its edge with a flat-head screwdriver, then pulling it from the inside door handle.

Turn the window crank so its handle points toward the front of the truck. Insert a window crank removal tool between the door panel and window crank, so the tools handle is perpendicular to the window cranks handle.

Press the window crank removal tool downward until you feel it contact the window cranks U-shaped clip you cannot see the clip, so you must do this by feel only. Hold one hand under the window crank and press the tool downward to disengage the clip. Catch the clip with your other hand as it falls out.

Pull the window crank from the window regulator input shaft. Hold the window crank in the same position it was prior to removing it the handle facing the front of the truck and insert the C-shaped clip into its slot on the rear of the crank, with the open end of the clip facing upward.

Insert a flat-head screwdrivers blade under the front-most part of the upper extension trim, the triangle-shaped trim piece above the front of the door panel. Pry outward on the front of the upper extension trim to release its retaining clips. Remove the trim from the door.

Pry the door lock lever assembly from the door panel, using a flat-head screwdriver. Pull the lock lever assembly off the door panel, which also disengages the lock actuator rod from the lock lever.

Remove the two door panel-retaining screws one in the lower front-most corner of the door panel and another inside the lock lever cavity using a ratchet and socket.

Slide the courtesy light assembly, if equipped, toward the front of the door to release its rear locking tab. Pry outward on the rearmost edge of the courtesy light assembly with a flathead screwdriver, then pull the assembly from the door panel. Twist the courtesy lamp socket counterclockwise and pull it from the assembly. Set the assembly aside.

Lift the door panel upward to disengage its retaining tabs and pull the door panel from the door, as you guide the courtesy light wiring through the courtesy light cutout.

Insert a flat-head screwdrivers blade under the doors water shield and into an area of the shields adhesive. Pull upward to break the adhesives seal, then remove the screwdriver. Using the broken area of the adhesive as your starting point, carefully peel the water shield from the door. Sit the water shield in a clean area with its adhesive side up.

Pull the window up to its full up position and have an assistant hold it in that position. Secure the window up with several 12-inch-long strips of duct tape.

Look inside the door, via one of the access holes, and find the two bolts securing the window regulator to the window glass guides, the fittings glued to the bottom of the window. Remove the bolts with a ratchet and socket.

Remove the four bolts securing the window regulator to the door, using a ratchet and socket. Fold the two sides of the regulator together and pull the regulator from the door, via the large access hole.

Guide the new regulator into the door and maneuver it until all of the bolt holes align and the regulators input shaft sticks out from its hole in the door. Tighten the regulator-retaining bolts to 80 inch-pounds, using an inch-pound torque wrench and socket.

Instruct your assistant to hold the window glass firmly as you remove the duct tape. Have your assistant lower the window until the bolt holes in the window glass guides align with their mounting holes in the regulator. Hand-tighten the regulator-to-window glass bolts, then tighten them to 80 inch-pounds.

Set the water shield in place on the door, guiding the courtesy lamp wiring, if equipped, and regulator input shaft through their respective holes in the shield. Press the water shield onto the door firmly with your fingers to stick its adhesive to the door. In any areas that the adhesive has become weak, add a strip of waterproof double-sided tape to replace the adhesive.

Guide the courtesy light wiring, socket and bulb through its cutout in the door panel, if equipped. Align the retaining tabs on the rear of the door panel with their slots in the door panel. Slide the door panel downward to guide the tabs into the slots in the door.

Insert the courtesy light bulb and socket into the courtesy lamp assembly, if equipped, and twist the socket clockwise to lock it into place. Insert the courtesy lamp assembly into its cutout in the door panel and slide it rearward to engage its retaining tab.

Align the window crank with the regulator input shaft and press the crank onto the shaft until you hear the U-shaped retaining clip snap into place.

Tighten the trim panels retaining screws to 18 inch-pounds, using an inch-pound torque wrench and socket.

Hold the door lock lever assembly up to its cutout in the door panel. Raise or lower the door lock lever, so the door lock actuator rod aligns with its retaining clip on the lever. Press the door lock lever assembly onto the door panel until it snaps into place.

Line up the retaining clips on the rear of the upper extension trim with the slots on the door. Press the trim onto the door until its clips snap into place.

Guide the inside door handle bezel over the inside door handle and line up the retaining tabs on the bezel with their slots in the door panel. Press the bezel onto the panel until the tabs snap into place.