Question on "snapping" sound in driver's door
 

Hello all,

The driver's side door makes a loud snapping sound as the door stay mechanism hops over those two little "bumps" in the door stay arm that make the door stop at the two positions. Yeesh...how do I describe this.... You know how you open the door and you can feel the two positions where the door stays open? Anyhow, I had bought a new door stay mechanism and reinforcement kit from our host, installed it thinking that something was wrong with the original stay. No dice. It still snaps. I remember reading about grinding down those two bumps in the door stay arm ...but I was looking at it closer this morning and it seems the pin that attaches the thing to the body of the car is actually loose. I inspected the passenger side (which has no issue), and rather than a pin, it has sort of a "split pin" kind of thing.

Anyhow, what is my car supposed to have? Should I locate a pin like the other side? Or maybe a larger drop-in type pin like the kit came with?

Any thoughts would be appreciated.

Thanks
Mark.

http://forums.pelicanparts.com/uploa...1354806379.jpg

Mark, I've had that issue occur before.....if I recall correctly, it was the stay-mechanism causing the pin to snap in the hole. I fixed my problem (after replacing the stay and reinforcing like you did) by putting in a larger pin to take up the slack in the hold. Try the larger drop in pin that came with your kit to see if it fixes the issue.

Thanks. I'll have to dig up the parts left over from the kit. It makes sense....I don't know why I didn't think of that back when I installed it. Was watching "Wheeler Dealer's" last night and they were working on a 911, and I was lamenting how my car snaps so loudly when I open the door compared to the one they were working on!

Make sure you don't have early stage damage on the metal in the door.

What would that look like? Originally I thought maybe the part attached to the body where the pin holds the arm might be loose...but the more I look at it, I think the pin is just not big enough.

+1

Common problem. If no damage, just try tightening the bolts on the door side, maybe?

http://forums.pelicanparts.com/porsche-911-technical-forum/645772-door-stay-question.html

I agree that the pin must take up all of the hole and sit firmly so that there is no chance of play and the resulting ovalation of the hole due to movement over time (wear).

The pin may be making the snapping sound, or the snap may be coming from sheared metal within the door, away from your eyes, First, be sure you have greased the curved arm of the stay itself, Next, if you feel it necessary, reduce the bumps using Vise Grips - ease it a bit at a time and test after adjustment.

I combined the plate replacement with other chores in the door (clean and grease regulator, etc.). At that time, I thoroughly cleaned the roller mech. that rides over those bumps. You might have a look at removing old grease if you have not already done so, and retighten your plates just to be sure they are firmly in place.

Thanks. Actually I installed the door stay reinforcement kit. There was some damage, but not too bad, and the kit helped sandhich the metal on the door and that is secure. I'm fairly certain it's not the door, but the part that's attached to the car's inner door frame. The clicking is coming from the spring action of that door stay when it rides over those humps - the click is the sound of the door stay snapping tight against the pin in the end attached to the door frame. There's play in the pin. The bolts on the door side are secure - In fact, when I removed the door stay, it looked brand new which makes me think the PO also had this issue and thought replacing the say would fix it.

I'm going to try to find some sort of pin that will fit more tightly and see if that clears it up. Aside from that, I'm thinking of removing the thing and grinding down those blasted humps on the arm...

Thanks for the tips. The mechanism is new, and I used the grease they supplied. Later I used some synthetic...and I've tried white lithium. I"m not sure I can squeeze those bumps down...I'm pretty sure they are solid on my car, but if not, that sounds like a good thing to try. But yes, I'll try a bigger pin. I agree...it's very possible that by now the hole is oval shaped :(

There are multiple threads on this. The John Walker fix is to use a 6mm bolt and nyloc nut in place of the press fit pin. Tighten just enough to prevent unwanted movement. No more pop.

-J

That's the fix (6mm bolt of the proper length, with nyloc nut). Has worked for many, including me.

I just fixed it! :) Went home over lunch and dug through my boxes of old BMW nuts and bolts and found a 6mm bolt and a locking washer. This has driven me nuts for 2 years! So satisfying when you can fix a constant irritation for free...

http://forums.pelicanparts.com/uploa...1354824891.jpg