These instructions were specific to a 2015 Dodge Grand Caravan with fixed glass in the sliding side doors, but may be applicable to other models.
General Tips
- Nothing needs to be forced.
- Use trim tools to pry.
- May need Torx 15, 20, & 30.
REMOVE Door Lock Actuator (with fixed glass)
To remove the door panel, first remove 2 smaller trim panels: 1st rear lower corner of window (pry front edge up about 1 cm. then lift the whole upward & forward), and 2nd, the panel surrounding the door handle (pry 4 clips toward the center of vehicle). Now exposed, remove one screw (upper forward of door handle).
Remove door panel, pry lower, front, rear edges inward until free, lift door panel upward to release the upper trim along the window glass.
Remove 10 mm hex head screw holding ground wire (rear of door). Separate wiring connector bottom of door, and separate harness leading to rear of doorr from the metal part of the door (harness can remain connected to the inner door panel.
Separate door handle from door (two more small torx screws, and two 10 mm screws). Without bending the door lock rod, un-clip it and remove from handle. Separate door latch cable from handle (depress two clips, pull away cable to lift thru slot, then swing cable to align slot to lift cable end from handle).
Protect the lock push rod by securing to the inner panel using the nearby built in clip.
Many cables do NOT need to be undone.
Open the rectangular access panel (front of inner door panel), disconnect the cable from the outside door handle (view thru slot along top of door, pull cable housing toward middle of vehicle, then swing cable to rear to drop terminal ball out of handle, then push cable guide to the inside of the door, then remove guide from cable, move cable from inside the door to inside the vehicle).
Open the rectangular cable connector (upper rear of inner door panel) and disconnect two cables running forward. Relocate the upper latch release cable to inside the door. Relocate the lower latch release cable to inside the vehicle.
Remove two 10 mm screws holding window channel (rearward of inner door panel, one behind hinge, one just forward of rear latch).
Remove three screws holding latch to door (outside rear of door).
Finally, remove the remaining 10 mm screws holding the inner panel to the door.
Remove in one piece, the inner panel, plastic actuator mounting plate, latch, and window guide (keep inner panel close to door, move a little forward, then simultaneously rotate the front edge upward and reach fingers inside door to lift latch over interior door support).
From the removed panel assembly, remove window guide rail (depress upper plastic clip while rotating guide forward to the slot, move guide just away from plastic plate then rotate guide rearward to expose the actuator rod clip, optionally to protect the fragile lower guide attachment slot, rotate guide about 200 degrees, to align the slot, and remove the window guide).
Disconnect wiring connector from actuator. Unclip and gently remove push rod from actuator arm. Alternatively, remove screw holding arm to actuator. Remove one small screw attaching actuator to mounting plate. Slide out actuator.
INSTALL Sliding Door Actuator
With the assembly reassembled, actuator and window guide rotated and snapped back in place, use the following tips.
Begin by rotating the assembly back into the door, keeping the inner panel parallel with the door. ASAP get the window guide centred on the glass (view thru slot between door and glass), then reach inside door to coax latch up and over the support inside the door.
Gently wiggle assembly into position (large guide pin over its hole in the door skin). Loosely secure by starting a 10 mm screw top middle.
Test the actuator operation (reconnect the ground strap and wiring harness).
Locate the two screw holes inside the door in the window guide rail with a pick or small screwdriver thru the inner door skin. Start the both the 10 mm screws without cross threading.
Install & tighten three door latch screws (locate latch with pick or screwdriver).
Reconnect three cables and test operation: outer door handle, and upper & lower front latch cables.
Start all 10 mm screws except the two for the inside door handle.
Reassemble, install, and test operation the inside door handle, including the manual lock lever. If door does not open, check the lock-out switch (bottom of the rear latch outside).
Tighten remaining 10 mm screws, including the two window guide rail screws.
Push the large outer door panel down into the slot between the door sking and the glass. Then, careful to align the push in clips with their holes, tap the panel into place.
Secure the front upper panel with the one remaining screw.
Install the remaining two small trim panels.