Replacing side sliding door, how do I switch popout glass?

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bamboopatch5
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Replacing side sliding door, how do I switch popout glass?

Post by bamboopatch5 » Sun Aug 18, 2013 4:40 pm

2000 Astro LS with dented side sliding door with pop out window. I got a replacement door at a PickAPart jy for $50, no glass or upholstered panel or interior trim (I've got those on dented door). My question is how to switch the glass onto the new door. I've searched the forums, only brief hints on this subject. Someone mentioned drilling out the top rivets on the window hinge-anyone done a installation by this method? Any details would be appreciated!
I recently bought this Astro van with 124k miles, well used and in need of attention. Thanks to this forum I've replaced door handles, power lock solenoids, checked out what shocks looked good (got Monroe Sensatrac, nicer ride), got overload springs (haven't installed the SuperSprings), etc etc. You Tube is great too. Mel

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Re: Replacing side sliding door, how do I switch popout glas

Post by doyoulikeithere » Sun Aug 18, 2013 4:57 pm

I have done the side pop out glass replace.
I tried very haard to get the screws out of the top 2 positions with a screwdriver.
Those screws have some sort of glue on them from factory and resist coming out.
The ones I could not unscrew, I drilled out. Be very carefull no to use too large of a drill bit.

In the end I said :butthead: to Chevy, and made up washers and screws to fix the ones I drilled thru, and the swap was a snap once I ruled out original GM parts.

The screws and special plastic bits are dealer items only. The stealership, when I priced out new bits, lived up to it's nickname "steralership" above and beyond the call of duty !!
Some of the parts are only available special order, and minimum full bag quantity. It was gonna cost me over a hundred bucks to replace 4 nut/screw washer combos from Chevy simply cuz they would force me to but 10 times more than I need, and of course the price of anything at the stealership is just a joke, even before they refuse to sell you 1 of something.
They would only get it in for me if I buy a full bag of 10 or more. !
Maybe the stealership in your area is less thief oriented in its sales approach, but that was my pop put glass experience with my local Chevy Dealer "Baljet GM" in Duncan BC. Way to go Baljet .
Now I understand why the Baljet family lives in a royal sized mansion surrounded by many acres, right on the ocean.
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bamboopatch5
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Re: Replacing side sliding door, how do I switch popout glas

Post by bamboopatch5 » Mon Aug 19, 2013 3:04 am

Yes, while at the junk yard I tried to unscrew the window fasteners with no luck, wouldn't budge and stripped the phillips head. So I was wondering if drilling the screws out might be the to go. Thank you Doyoulikeitthere for you response.
But I'm still wondering if drilling out the top rivets on the hinge and then riveting the whole window assembly also works??

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Re: Replacing side sliding door, how do I switch popout glas

Post by doyoulikeithere » Mon Aug 19, 2013 3:08 am

Sounds reasonable enough, should work fine.
You will have to remove all of the interior trim to get in there. So in your case your already there.
I drilled a couple of the phillips screws and backed up the new ones with some rivet washers that fit into the plastic cups..
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Re: Replacing side sliding door, how do I switch popout glas

Post by Captn. Crunch » Wed Nov 13, 2013 6:34 pm

I just had my window replaced and had the same issue with not being able to back out those screws. They are factory lock-tited. I took a soldering iron and held the iron on the head of the screw for a minute. They came right out!
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Re: Replacing side sliding door, how do I switch popout glas

Post by Kidhauler » Fri Nov 15, 2013 4:49 am

If you look in the how to or pinned topics there should be a post I did on swapping the rear windows. The same basic steps should apply. It should be easy to put new rivets in the new door as you have factory holes in place you will not have to drill mount holes.
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