nkgosselin

Car has 140k miles on it. 86 Turbo.

First the TIP:
Run some string through the white tab that attaches to the lock on the back of the handle and drape over door. Makes it 1000x easier to handle it and reattach. Trust me, I had this handle on and off a dozen times today.

Questions:
The passenger side has typical 'can't open from outside' symptoms.

Just adjust the rod, always the answer.

Adjusted rod ALL THE WAY, I mean it had only 1.5 threads engaged. Still no joy.

So, I shimmed with metal and epoxy the handle to take out any slop. (someone on here had done this before) Still no joy.

While watching it operate the rod simply does not push down the lever far enough.

SO, is it it the handle most likely still?
Or, in looking closely, the lever on the actual lock mechanism has a ton of play it it. Could that be worn to the point of causing not enough travel?

Would be a bummer to need both lock and handle...

Tiger03447

Please tell me how you were able to re-attach the white piece to the little **** on the backside of the handle. I can get my finger on it, but there seems no room to push it on..screwdriver doesn't seem to hack it. Custom bent screwdriver?

nkgosselin

The string.

With it you can pull it into place, hold it there with tension, then use a flat blade screwdriver to press it on.

porscharu

A dab of grease on the ball helps it pop on too. Great idea with the string. The upper one accessed through the door opening wasn't as bad as the lower. It is just hard to see AND leverage at the same time.

Tiger03447

Thanks guys for the tips...Maybe I can get mine to go back together better next time I have the door card off.

pdxfj

I just went through this and discovered if you remove the vent in the side of the door and look up, you can see the lower ball joint. I used a 2' long, 3/8" extension to reach up and pop it together. The ratchet end of the extension was thick enough to give a bit more leverage on the joint.

Also helped to have the handle bolted back into place so nothing would move when trying to pop the lower joint back together.

bonus12

Nice. I need to at least put new seals on mine so thanks for this additional info!

Tiger03447

Thanks pdxfj perhaps now I won't have to take the door card off (again). I'll give it a shot..can't remember if it was the upper on the lower one, but I think it was the lower..I'll put an intense eyeball on it..

pdxfj

Yes, it's the lower one. The upper one can be done before securing the handle to the door. Just make sure the arm for the lower joint is in the right place before bolting the handle down. You'll need to lie on your back to see up into the door.

Did this first on the driver's door and when I got to the passengers door, it took less than two minutes and I was one.

Hopefully it goes smoothly for you.

snb13

I've had my driver's door handle apart a few times. In fact just a couple weeks ago. No need to take the vent out, lay on my back or use a string. It's always popped on just fine.

Otto Mechanic

This is a great trick, so I tried it. But I'm darned if I can get the black plastic part to seat over the ball (the part that's threaded onto the drop link).

Using this method I've had plenty of clearance to get a screwdriver in there and I can even sneak a finger in, but I can't put enough pressure on the plastic part to get it to snap onto the ball? I greased it, tried with a thin screwdriver, went to a thicker screwdriver, snuck a finger in, then cussed at it.

None of the above worked. I'm thinking maybe I should cuss at it before putting the screw driver in? Maybe I'm not using the right cuss words?

Otto Mechanic

PS: I've tried "You Godforsaken excuse for an Engineer!" and "What the f**k were you thinking!"

Neither have worked. Suggestions and alternate incantations appreciated...

Otto Mechanic

One more thought: Is the black plastic thing threaded onto the drop link supposed to engage the ball with the round hole at the bottom (my thought) or the sort of rectangular hole above it? To me, the rectangular hole doesn't make any sense (round peg, square hole, the rest follows logically), but maybe that's my problem? One of those "conceptual difficulties" I seem to have over and over again when working on these cars?

Otto Mechanic

And for goodness sake, how do you get the "vent in the side of the door" out to begin with? That could maybe help?

Tiger03447

Try pushing it to the side a bit..I think it has tangs on the underside lip..If I remember correctly. Use a small screwdriver to release the tangs and it will come right out. One side at a time..hope this helps some. If you break the tangs off getting it out..no biggie. A bit of cement will hold it all together for the next time..