How to Remove the Door Panels on a 2006 Chevy Cobalt

The Chevy Cobalt took the place of the Cavalier, which had a 24-year run. During its production, the Cavalier had been considered the best selling car in America. The Cobalt, other than body changes, uses the same powerplants as the Cavalier, with the exception of the supercharged Cobalt SS. Removing the door panel from the door is relatively easy. The panel is held securely to the metal door by plastic trim fasteners. These fasteners are shaped like a screw with a large flat head. The fastener head is inserted into a cut-out pocket in the door. The shank is pressed by hand into recesses in the metal door.

Instructions

1

Open the door and lower the window glass. Remove the plastic cover behind the inside door handle. Look at the rear oval cover and you will notice a small notch above the handle. Place the small screwdriver into this notch and pry the cover off. Remove the two screws behind the door handle.

2

Remove two screws below the armrest pull handle recess by prying the recess out with the small screwdriver, yielding access to the two screws. Pry the window switch panel out of the door panel using the small screwdriver to pry up the backside of the panel. Lift the rear of the panel up to release the front clip.

3

Unplug all electrical connectors from the rear of the switch and lay the switch aside. Remove the two screws below the switch panel. Insert the standard screwdriver under the lower rear corner of the door panel. Slide the screwdriver up the rear of the panel until the screwdriver contacts a trim fastener. Pry the fastener out of its recess in the door and move upward to the next and repeat the process. Move the screwdriver down and continue the process on the bottom of the panel and the front side until all fasteners have been removed.

4

Swing the bottom of the panel out a small amount and lift it up to release the top of the panel from the top door sill. Unhook the door handle cable from the back of the door panel by pulling the cable out of the rear housing. Lift the cable up and detach the ring on the end of the cable from the door handle.

5

Install the panel by holding it close to the door and connecting the door handle cable to the rear of the door handle. Insert the circular end on the door handle and lower the back of the cable, give a little pull on the cable toward the rear of the vehicle and slide the cable into its pocket in the door panel.

6

Tilt the door panel up and latch it on the top of the doorsill. Lower the panel and align the trim fasteners with the holes in the door. Press all the trim fasteners into their respective holes.

7

Install the two screws below the window switch followed by the window switch. Connect the electrical connectors and push the front of the panel clip into the hole in the panel and lower the rear of the panel and snap it into the door panel.

8

Install and tighten the two screws in the armrest handle recess and insert the plastic recess cover. Install and tighten the screws behind the inside door panel. Install the plastic cover behind the handle.