Loving Corvettes--and particularly older Corvettes--requires a special commitment on the part of the enamored, inasmuch as the cars' laudable driving dynamics tend to be at least partly overshadowed by a litany of marque-specific mechanical foibles. And while improvements in design, material quality, and production techniques have gone a long way toward erasing bad, old memories of dodgy vacuum systems and leaky brake seals, even recent iterations of Chevy's fleet two-seater are susceptible to a few well-documented equipment failures.
In the case of the C5, two such failure-prone items are the power-lock actuator and the window-regulator assembly. Fortunately both parts are located just behind the door panel and are easy to access using basic hand tools. What follows is an overview of the replacement process--one that even a novice mechanic should be able to perform in around an hour (per side).
1 Start by prying off this...
1 Start by prying off this cover plate to reveal the two bolts that secure the door panel.
2 Next, remove the bezel...
2 Next, remove the bezel around the door-latch mechanism, followed by the switch plate.
3 With that done, unplug...
3 With that done, unplug the wiring harness from the back of the plate.
4 Remove the two retaining...
4 Remove the two retaining bolts and gently pull on the door panel to free it from the retaining clips.
5 With the panel removed,...
5 With the panel removed, the door should look something like this. Don't be too concerned if the black-rubber isolator panel has deteriorated. You'll need to remove it in order to access the inside of the door, anyway.
6a Remove the three bolts...
6a Remove the three bolts securing the striker assembly to the doorframe.
6b. With that done, unbolt...
6b. With that done, unbolt the latch mechanism and separate it from the door.
7 At this point, you should...
7 At this point, you should be able to pull the striker assembly out through the door opening and unplug the attached lines.
8 Unbolt and separate the...
8 Unbolt and separate the from the old power-lock actuator from the rest of the assembly…
10 Once you've bolted everything...
10 Once you've bolted everything back into place, verify that the new actuator is working properly by pushing the lock and unlock buttons on the switch panel.
11 Moving on to the window,...
11 Moving on to the window, remove the two bolts that hold the glass in place.
12a With that done, lift...
12a With that done, lift out the glass and set it aside in a safe place.
12b The rear cargo area is...
12b The rear cargo area is as good a location as any.
13a Remove the seven bolts...
13a Remove the seven bolts holding the window regulator assembly in place.
13b Start with the two at...
13b Start with the two at the top of the door, followed by the three in the middle that hold the window motor in place.
14 The sixth bolt is located...
14 The sixth bolt is located at the bottom of the door...
15 ...while the seventh is...
15 ...while the seventh is on the underside, concealed by a protective rubber plug.
16a Once the regulator-assembly...
16a Once the regulator-assembly bolts are out, remove the speaker panel.
16b This will create a second...
16b This will create a second opening through which you can reach as you manipulate the regulator free of the door.
17 Here's a look at the regulator...
17 Here's a look at the regulator assembly out of the car. Replacement units are available from your local Chevy dealer and most large Corvette-parts retailers for around $300. Lovell recommends the genuine GM part, having had poor luck with less expensive knock-offs in the past.
18 Reverse the previous steps...
18 Reverse the previous steps to install the new regulator. Once that's done, lower the window glass back into place.
19a Check the fit of the...
19a Check the fit of the glass using the
19b You want the bill to...
19b You want the bill to be held firmly between the glass and weatherstripping when the door is closed.
20 Dial in the right fit...
20 Dial in the right fit using the four adjustment bolts on the door. These are the same bolts that hold the regulator assembly in place (minus the three that secure the motor). Remember that one is located on the underside of the doorframe.
21 Finally, verify that everything...
21 Finally, verify that everything is working properly by running the glass up and down a few times with the switch panel. Reinstall the door panel, then head out and enjoy your freshly reconditioned lock and window mechanisms.