Broken door handle hinge replacement: nasty!!
07-13-2005, 12:13 AM
#1
Three Wheelin'
Thread Starter
Broken door handle hinge replacement: nasty!!
Well I spent many hours today fixing my inop driver's side outer door handle. What a trial.
First, I've got to recognise George Suennen for posting a great writeup on the procedure (http://sis125.berkeley.edu/928/wk-door-handle.html). I wouldn't have tackled the job without it.
Everything went well until it was time to remove the lock motor. I couldn't see how to get it out, so I decided to leave it in situ and work around it. I did remove the security plate (or whatever it's called) that sits behind it, though.
I don't know if my decision was wise, as I spent a good deal of time contorting myself to gain access to the part. It's really tucked up inside the door. If you've got big, heavy hands, send out for this job!
In all it went pretty well, though I spent about 5 hours futzing with it. I think it would have been a lot faster if I'd had one of those ratcheting box wrenches in a 10mm size for the hinge nuts. I guess by time it was about as long as others cited, and just as frustrating.
For those thinking of doing the job, in addition to the racheting box wrench, I'd suggest a set of long hex keys w/ the ball end for working on an angle, extra door panel clips, and spray adhesive to resecure the plastic barrier.
The new hinge was about $50 bucks from 928 Int'l.
First, I've got to recognise George Suennen for posting a great writeup on the procedure (http://sis125.berkeley.edu/928/wk-door-handle.html). I wouldn't have tackled the job without it.
Everything went well until it was time to remove the lock motor. I couldn't see how to get it out, so I decided to leave it in situ and work around it. I did remove the security plate (or whatever it's called) that sits behind it, though.
I don't know if my decision was wise, as I spent a good deal of time contorting myself to gain access to the part. It's really tucked up inside the door. If you've got big, heavy hands, send out for this job!
In all it went pretty well, though I spent about 5 hours futzing with it. I think it would have been a lot faster if I'd had one of those ratcheting box wrenches in a 10mm size for the hinge nuts. I guess by time it was about as long as others cited, and just as frustrating.
For those thinking of doing the job, in addition to the racheting box wrench, I'd suggest a set of long hex keys w/ the ball end for working on an angle, extra door panel clips, and spray adhesive to resecure the plastic barrier.
The new hinge was about $50 bucks from 928 Int'l.
07-13-2005, 12:46 AM
#2
928 Barrister
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I've done that job, and you left out antiseptic and band aids for skinned knuckles and other body parts, and soap with which to cleanse your mouth after finishing after all of the foul language used. Hope I never have to do it again. 
07-13-2005, 12:52 AM
#3
Drifting
You get used to it eventually, I can do it in under an hour in and out now. I know where everything is by feel and what needs to be removed and what doesn't to save time. It only took about a dozen before I got the hang of it.
07-13-2005, 01:27 AM
#5
USMarine
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Originally Posted by Ketchmi
You get used to it eventually, I can do it in under an hour in and out now. I know where everything is by feel and what needs to be removed and what doesn't to save time. It only took about a dozen before I got the hang of it.
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07-13-2005, 06:06 PM
#9
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Oh god I've done this job! I have narrow hands with long fingers [I know I should play guitar, but I don't-no interest, sorry] and I didn't think this job was all that bad.
The main thing I remember is that you have to get the door lock servo out of the way [my '85 has an electrical central locking system; if yours is vacuum actuated, then my advice is not applicable]. Once you've done this, just make sure you have a supply of long allen wrenches, you know- at least 3 inches long. I have a pair of needle nose pliers I got at a bait shop- their "fingers"- or the part that actually sticks forward and grips...is about 6 inches long. I remember using the hell out of this last pair!
The long and short on this job is that you have to make it enjoyable. I did it on a sunny afternoon, with the car backed up the drive, the doors open, the stereo in the garage playing, and a couple of Corona's nearby. Get your girlfriend around too; if your hands are too big you can enlist her help!
Best of luck!
N!
The main thing I remember is that you have to get the door lock servo out of the way [my '85 has an electrical central locking system; if yours is vacuum actuated, then my advice is not applicable]. Once you've done this, just make sure you have a supply of long allen wrenches, you know- at least 3 inches long. I have a pair of needle nose pliers I got at a bait shop- their "fingers"- or the part that actually sticks forward and grips...is about 6 inches long. I remember using the hell out of this last pair!
The long and short on this job is that you have to make it enjoyable. I did it on a sunny afternoon, with the car backed up the drive, the doors open, the stereo in the garage playing, and a couple of Corona's nearby. Get your girlfriend around too; if your hands are too big you can enlist her help!
Best of luck!
N!
07-28-2005, 05:37 PM
#11
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Bloody hell. My driver's side door handle just let go this morning. After reading this thread, I guess I can plan to devote Saturday to fixing it instead of installing the 928SP HID Bi H4 kit I just received yesterday.
Great... just great...
Thanks, George, for the write-up. I'm sure I'll be using it within the next few days.
Great... just great...
Thanks, George, for the write-up. I'm sure I'll be using it within the next few days.
07-28-2005, 06:31 PM
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Ed- As I said before...you are literally doing surgery on your 928. Make it enjoyable!
If you have big hands, I really suggest getting your wife/girlfriend/kid to help you with this. It really isn't too bad, it's just that the part is hard to get to, despite the fact that you can see it easily.
-NOTE: I have very good eyes. I can almost focus on the tip of my nose, and can [sometimes] read a license plate 1/4 mile ahead. Those of you that need reading glasses- put them on for this job!!!
Again, get that servo out of the way and this isn't too bad, and buy a long pair of needle nose pliers. Best of luck!
N!
If you have big hands, I really suggest getting your wife/girlfriend/kid to help you with this. It really isn't too bad, it's just that the part is hard to get to, despite the fact that you can see it easily.
-NOTE: I have very good eyes. I can almost focus on the tip of my nose, and can [sometimes] read a license plate 1/4 mile ahead. Those of you that need reading glasses- put them on for this job!!!
Again, get that servo out of the way and this isn't too bad, and buy a long pair of needle nose pliers. Best of luck!
N!
07-28-2005, 06:36 PM
#13
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Originally Posted by chaadster
First, I've got to recognise George Suennen for posting a great writeup on the procedure (http://sis125.berkeley.edu/928/wk-door-handle.html).
07-28-2005, 06:52 PM
#15
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Originally Posted by Normy
Ed- As I said before...you are literally doing surgery on your 928. Make it enjoyable!
6-pack of Paulaner ... check
Big, honkin' fan ... check
Parts, overnighted from 928SP ... check
OK, ready.
Originally Posted by Normy
It really isn't too bad, it's just that the part is hard to get to, despite the fact that you can see it easily.
Originally Posted by Normy
NOTE: I have very good eyes. I can almost focus on the tip of my nose, and can [sometimes] read a license plate 1/4 mile ahead. Those of you that need reading glasses- put them on for this job!!!
Originally Posted by Normy
Again, get that servo out of the way and this isn't too bad, and buy a long pair of needle nose pliers. Best of luck!