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How-to » Body & Interior » Exterior » How to Replace a Door Shell
 Note: This is a general guide for all vehicles.

How to Replace a Door Shell

PARTS
  • Door Shell
TOOLS
STEPS
Edit
Hard
Safety Tip:
Always wear safety glasses when working on your vehicle. Wear other personal protective equipment (PPE) when necessary, for example latex gloves or closed toe shoes.

1
This guide does not contain instructions for painting this part. We highly recommend you complete painting the part before installing it.
2
Safety Tip: Always wear safety glasses when working on your vehicle. Wear other personal protective equipment (PPE) when necessary, for example latex gloves or safety shoes
3
Locate the damaged door.
4
Remove the interior door panel from your door.



Tip: Remove the armrest, window, door lock switches/levers, and/or a door handle to remove the panel. An interior trim tool or pocket screw driver would work best.
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5
Remove any and all parts that are salvageable from the door and can be re-used on the new door. (Side Mirror; Window Glass / Motor / Regulator; Weather stripping; Door lock mechanism and door handle; Door speakers)
6
For any wiring that was disconnected from the door, be sure to pull out the harnesses from the door and remove the rubber grommets. These can be used for installation.
7
With the aid of an assistant, hold the door in an open position and remove the door from the frame mounted hinges.

Tip: Leaving the hinges attached to the vehicle's frame will help with realignment of the new door.
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8
With all components disconnected from the door and the door removed, match the new door up to the old door to confirm that you have the correct door shell.
9
Mount the door shell to the hinges and check for proper alignment.
10
Determine which hinge bolts need to be loosened to move the door in the correct direction.
11
Do not over loosen the bolts when adjusting, loosen them enough so you can carefully and slowly make small adjustments to the doors alignment.



Tip: The goal is for the door to fully open and shut without corners rubbing on the body. There should also be equal gaps all the way around the door.
12
Once the door is properly aligned, tighten the hinge bolts to the manufacturer's specifications.
13
Reassemble all interior door components that were taken off during door removal.



Tip: It is a good idea to test the accessories such as the window, mirror, door locks, and other accessories as they are being put on for proper operation.
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14
Mount the interior door panel and components to the door shell.
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