morghen

In your first picture it looks like the shape of the handle is not following the shape of the recessed area in the door. Any more pics ?

Arominus

Are any of you cleaning up the door latch? because gummed up releases/lock assemblies really accelerate the wear/stress factor on the handles. If you haven't done it, you really should. Its a dirty, time consuming job but it really make the doors release from the handle much easier.

88Silver924S

I have never had a door handle break so I'm not sure what the problem is but to reduce stress on the handle make sure the strike on the door pillar is adjusted to keep the door closed but no tighter than needed so there is no extra stress on the mechanism. Loosen the two bolts and move the strike until you find the sweet spot. It is a trial and error adjustment. Finish with a smear of grease or grease stick.

RoyaleWithCheese

I think it may be a climate thing.

The ones I have had break have all happened on very cold days when the grease in the door mechanism is extra stiff and tacky.

I have had the actual lever break off, that plastic tab I mentioned on the VW set, and multiple non-repairable inner pieces break on various handles. The car now sits in the garage with both doors open during the winter so that I can work on it but not have to use the handles at all.

Arominus

Pull the mech and clean it, once i've done that the doors open great even in the cold. Its really worth your time to do it in colorado. My doors opened easy even after a -25f overnight cold soak in keystone a few years ago.

Tiger03447

I have an issue with my passenger door handle..If I guess correctly, when you squeeze the trigger to open the door, the linkage rod must move down. I have the handle off, and it doesn't do anything when you squeeze the handle..the two little cast rods come up, but that is all. there seems to be some very thin cast parts that have broken off some of the mechanism..but I'm baffled with this rig..I've never worked with one of these before, and there are no good pics to look at to see how it functions. Help, please. Thanks, Tiger 03447

nitehawk951

FRporscheman, thanks for the pics. I'm having so much trouble reinstalling the driver door handle after replacing that door lock linkage part (#944-537-261-02-M100). How did you get that door lock linkage part to go in front of the little ball it connects to? For me it keeps sliding off track and I can't get it aligned properly. I have the door panel off already but have to remove the window motor to make this job any easier. Not looking forward to that. If you don't see this soon I'll PM you for some help if you don't mind. This is a real bitch.

I agree with you Chris, next time I do this I'm going to mask off the door. Such a pain.

Tiger03447

Guys...The pot metal bellcrank with the link is the part that I am in the process of trying to make out of 2024 aluminum..I know that they are expensive, for the part, but with the engineering costs, the set up and machining time, I can't get the price lower until I get about 20 -30 sets on order.. so for right now, if you want a pair of rt & lft bellcranks, they are 90/pr or 50 for one..I have 3 orders for them now..so step right up and I will get them to you as soon as I can..then you can quit worring..you'll have to use your old link with the plastic end on it - but i will send along a small bolt and a stainless nylock nut for it...thanks, Tiger 03447

FRporscheman

PM replied.

BTW, I can report that after 8 months the VW handle is still working great. I love not thinking about it breaking every time I grab it.

D.white88

This worked like a charm, after some filing, and fitment. longest part was fidgeting with the window reg. Thanks for the tip!

B_2

I don't want to be a bore, and i also looked at the Golf 1 handles.They are also a great resource for lock parts.
Just mind that the wood piece will likely deteriorate over time. i.e. rot/crumble. Otherwise, i am all for it.