DIY Speaker grill replacement...

**pondside36** · 07-16-2008 08:34 PM

I know this sounds real easy but it isn't... with that being said this should make it easy and save you some money in the process.

My passenger side rear speaker cover was cracked and was bothering me every time I saw it; so I went to the dealer and bought a new one not realizing that it isn't just screwed in to the door card..

So to make a long story short, I searched inspected the inside to find that the cover is plastic welded into the door card and would take a little more time.

So here it is:

Tools:
Drill
Drill index
Philips Screw Driver
Butter Knife
Stove
painters tape

Parts:
New speaker grill
Quick clips that help secure the door card

1. Start by removing the door card. This is done by removing the belt line trim. Pull from the front of the door and it will pop away, note hooked end for reinstall.

2. Remove three screws behind belt line trim and one screw under armrest in recessed hole. You should look like this.

3. Gently pull door card bottom out, you'll hear snapping and may brake one of the quick clips (hence why you may want a few) This what they look like.

Then pull the sides off and pull the card up out of the door. It is a little tricky but you'll get it. There are also two small whit quick clips on each end of the top of the door that you have to pull hard to get off.

4. Next remove all connection to door and door car, door handle cable, speaker plug, and window regulator plug.

The orange one and there is a clip on the back that you depress and pull down.

5. Sweet, now you have the door card off and the work begins..

6. I used a drill to break the plastic welds on the back of the speaker grill. I started with a small 1/8" and when used a larger 3/8" drill bit to break the remaining plastic away. Take your time so you don't break the plastic tabs on the door card.

No screws..

Time to drill..

Pop out the old grill...

Wow that thing was hammered..

7. Now you can install the nice new grill. I used the painters tape to secure the grill in place nice and flush and then supported the back for the next step with a phone book may be thick enough if you live in a city but may need another book.

Now you get to do the DIY plastic weld. I used a butter knife and the stove. If you don't have a gas stove this may be tough but I'm sure a soldering iron or torch could assist in this process.

Press firmly until exposed plastic is melted flush with tab and pull away as to not get the knife stuck to the door. It should look like this when you are done.

8. New grill is in so all that is left is to reinstall the door card in reverse. The screw on the bottom of the handle is a pain, I would recommend a magnetic screw driver and also to make not of how it goes in while the card is off.

9. Sit back and admire a job well done and have a frosty adult beverage if your of age..

Comments or suggestions welcome..

**agart** · 07-17-2008 05:07 AM

Well that helps alot... I made the mistake of prying mine off thinking it was just some pop off tabs, to quickly find out it wasnt going in. I got a new cover and I've had it in its spot but it keeps falling out. I thought I had to get a special tool to expand the tabs.

on the DIY.

**pondside36** · 07-17-2008 06:31 AM

Yeah that is why mine was so hammered, my brother thought he would help me out and replace it for me while I was away to discover it just broke more as he pulled on it... I hope it works out for you and remember to take your time with removing and reinstalling the door card so you don't break to many of the quick clips..

**skeeball** · 07-17-2008 07:46 AM

Thanks, Pete. I need to do the same thing. My girl broke my passenger side one a while back.

**Gom33** · 07-17-2008 07:50 AM

this is very helpful.... my wife has been bothered by our speaker grill being cracked from day 1, lol... will have to pick up new grills next week and switch em out... thanks for the diy!!!

btw... how much did a new grill cost at the dealer?