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HOMESERVICE MANUALSCHEVROLET2000CHEVY EXPRESS G3500, VAN CARGO EXTENDED, 6.5 FREPAIR AND DIAGNOSISBODY & FRAMEWINDOWSPOWER WINDOW SYSTEMREMOVAL & INSTALLATIONWINDOW MOTORREMOVAL & INSTALLATION (ASTRO & SAFARI)
2000 Chevrolet Chevy Express G3500, Van Cargo Extended, 6.5 F

Removal & Installation (Astro & Safari)

2000 Chevrolet Chevy Express G3500, Van Cargo Extended, 6.5 FSECTION Removal & Installation (Astro & Safari)
  1. Raise window to full up position. Disconnect negative battery cable. Remove 2 armrest cover screws and remove armrest cover. Remove lock lever escutcheon by pulling out and away from trim panel, starting at front. Remove upper corner trim from door by pulling out on top edge and pivoting down to clear tab at trim panel.
  2. Remove assist handle retaining screw covers. Remove assist handle retaining screws. Remove door switch mounting plate. See WINDOW SWITCH  . Gently push courtesy light lens toward front of vehicle. Using flat-blade tool, pry rear of courtesy light lens away from trim panel and front retaining tab on lens. Remove courtesy light assembly from door.
  3. Using Trim Pad And Garnish Clip Remover (J-38778), pry trim panel from door near retaining clips. Remove trim panel from door and set aside. Remove inner panel upper bar from door. Remove water deflector.
  4. Apply cloth-backed body tape from window over top of door to other side of window to hold glass in position when regulator is removed. Disconnect wiring harness from regulator motor. Using 1/4" (6 mm) drill bit, remove regulator-to-door rivets.
  5. Push regulator into door, and slide in and forward. Then push rearward to remove regulator arms from sash and regulator rail. Fold regulator arms together and remove regulator through access hold.
    6. CAUTION: Next step must be performed when regulator motor is being removed from regulator. Regulator lift arms are under tension from counterbalance spring and can cause serious personal injury if motor is removed without first locking sector gear in position.
  6. Install a self-tapping, pan head sheet metal screw through sector gear and backing plate at hole provided to lock sector gear into position. Drill out motor-to-regulator attaching rivets. Remove motor from regulator. To install, reverse removal procedure. Lubricate motor drive gear and regulator sector teeth. Check mesh of motor-to-regulator before installing NEW 1/4" (6 mm) rivets.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.