How To Replace Rear Door Panel 2003-12 Volvo XC90

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In this video, we're going to show you how to remove and reinstall the rear door panel on this 2004 Volvo XC90, pretty much the same as any '03-'12 XC90. The tools you'll need are a flat blade screwdriver, a T25 Torx driver, and either a door panel clip tool or household putty knife will work as well.

Okay, you're going to start out, there are three clips that hold the little bezel on the door pull. The clips are at each end and then on in the middle. Carefully work a screwdriver underneath, pry up and out, and release that bezel. It comes up and off. Then, in behind, there are two T25 screws. Use a T25 socket with a ratchet and extension, or you can use a regular driver, and remove the two screws. Here I'm going to speed it up a little bit as I remove those screws.

Now you're going to use a household putty knife or a door panel clip tool, work it between the plastic panel and the metal door, and you'll slide it up, come to a clip, and then pull quickly and firmly and release the clip, slide it down to the next one, do the same thing, and just keep working your way right around the door. Like I said, there's clips at the bottom and then in the back. Once you have the clips around the perimeter released, then there's two clips in the middle of the door, so grab firmly or grab hold of both the front and back of the door panel and pull firmly to release those two clips.

Now, on the back side you have your door handle cable. This is two clips, just try and separate those, pull the cable firmly, it comes off, and then there is a connector for the window switch. There is a little release button that you have to push on. Find that button, push on it, and disconnect the switch. The button is actually towards the front of the vehicle.

Put the panel back on, check all your clips. One of mine did come out. Just put it back in place. The door panel is in close. Reconnect our power window switch. Take our door locks handle cable and you just press it right into place. Just doing a little quick test to make sure that the handle activates the cable. Put the door handle in place. Make sure you put the door lock knob through. Just kind of peek back and line up the clips. Same thing over here.

Actually you're just going to have to almost line it up a little bit by feel. Put it back on. Take our two T25 screws. I'll speed it up here as I put those screws back in, tighten them up nice and firm. When you put this back down in it's got two tabs that go down in here. You kind of put the side closest to the door in and down first, and then snap the outer side in and it's all set.

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