Broken door handle repair

Zeloy · 12-19-2004, 11:40 AM

So the driver's side exterior door handle on my '83 is broke. I've done searches on pelican for this and it seems there is probaly a small metal rod that is broke. A new door handle is around $125, ouch!

I'm home from school now so I actually have some time to work on this and I'm trying to get around buying a new part. My plan is to remove the inner door panel, find the small metal peice that is broke, replace the door panel, drive back to school to have a new part machined for me and then install this new part. I've never messed with the doors of my car before so I'm not sure how hard this will be. Is it even possible for me to remove this broken metal piece and then put the door back together so it can be driven (using passenger side door)? By the way, the passenger side door doesn't open from the outside without applying extreme pressure any ideas there? I better get these problems fixed soon or I'll be going in through the hatch! Let me know what you think I should do, or any advice on performing this repair, thanks.

Karl2bdc · 12-19-2004, 12:03 PM

If it is the curvy metal piece, that is about 20 bucks, you can pick them up on ebay all the time...it just attaches to the door handle. Taking off the interior door panel will not give you any access to the part. You have to do it from the outside.

bearone2 · 01:59 PM

the way most break, at the pivot point are not reparable. if you can it probably won't last.

i got one from a wrecking yard, took a few adjustments, which can be aggravating/difficult, to get it to work.
i took the cylinder out of the old handle to use the same key.

seems it was $50 and i can't remember who i got it thru.

nynor · 12-19-2004, 03:55 PM

it is most likely this little dog-leg piece. you have to take the door panel off, to unhook a nylon pivot joint, you also have to take the handle off by removing a screw from the door in the doorjam area. the fix is incredibly simple. the part will cost around $30. i think i got mine from 944online.com.

Don 944 LA · 12-19-2004, 09:06 PM

I got a used one off evilbay a while back for like $20 . works like a champ. I had the pivot piece break.

Zeloy · 12-20-2004, 06:06 AM

Quote:

Originally posted by Karl2bdc
If it is the curvy metal piece, that is about 20 bucks, you can pick them up on ebay all the time...it just attaches to the door handle. Taking off the interior door panel will not give you any access to the part. You have to do it from the outside.

Just to be sure, I do need to remove the inner door panel to replace this part correct? Also, am I correct that I will only need to buy a new metal dog leg piece or are you saying I should just buy a whole new handle? I don't see any up on ebay at the time, I'll keep my checking though.

nynor · 12-20-2004, 06:27 AM

i would take the handle out just to be certain... its broken anyway, so its not more inconvenient without a door handle. you will need to take the inner door panel off. try 944online.com for the part. pelican may have it, too.

dave24 · 12-20-2004, 09:20 AM

Same thing happended to the drivers side handle on my 84 yesterday.
Look at the write-up at the Clarks Garage site. They describe how to do this from the outside. Doesn't sound too hard... I'll be trying it this week myself.

Dave

nynor · 12-20-2004, 10:24 AM

i don't think the nylon piece can be attached from the outside.

Karl2bdc · 12-20-2004, 10:40 AM

You do not have to take the door panel off, i have replaced many and never taken an interior panel off, you will need a piece of wire or an allen wrench to get that plastic arm to swing up to the door handle so you can attach it.

Karl2bdc · 12-20-2004, 10:41 AM

Oh and this is one of the those little jobs that one time will go so easy, and the next time will take you a half hour of cussing to get everything into place, lol.

bearone2 · 12-20-2004, 10:50 AM

Quote:

Originally posted by Karl2bdc
You do not have to take the door panel off, i have replaced many and never taken an interior panel off, you will need a piece of wire or an allen wrench to get that plastic arm to swing up to the door handle so you can attach it.

i couldn't get the plastic locking piece back in place without taking the door panel off.

nynor · 12-20-2004, 12:13 PM

i'd love to see someone get the nylon piece to come off of my door handle, without the panel removed... it took a LOT of force to get that thing to snap back together.

Zeloy · 12-22-2004, 09:33 AM

Just thought I'd give everyone an update. Today I tried to remove the door handle without removing the inner door panel based on the procedure at Clark's garage http://www.clarks-garage.com/ The first three steps went easy in under 5 min., the fourth step screwed me. The dog legged piece which I assumed to be broke was actually fine, I could not however remove it from the ball joint. I pryed and pryed but it wouldn't come out. Eventually the thin plate of metal that attached the dog legged rod decieded to break off instead leaving the rod still attached to the car

. I still can't remove the dog-leg rod from the door, maybe it's time to remove that paneling...sigh

nynor · 12-22-2004, 09:39 AM

oh man...

Karl2bdc · 12-22-2004, 09:50 AM

It takes 2 screwdrivers to pop that nylon piece off the metal ball from the outside.

VaSteve · 12-10-2005, 11:33 AM

For the archives...if you have the black metal track for the window...unbolt the three bolts holding on the smaller piece (near the top). Then reach inside and undo the bolt at the bottom. You can then bend/nudge the piece out of the way so you can reclamp the lock and latch mechanisms. Bend/nudging that part does no damage to it.

NKN84944 · 12-10-2005, 04:18 PM

Yeah it is much easier to take off the door panel IMHO, especially when putting it back together. A great resource for this with nice pics can be found here or here .

Good luck