IcemanG17

Okay I knew this would happen!

On Gerry's 78 the drivers side door handle has the standard broken part. Taking it out really wasn't that bad at all, so I was suspicous it couldn't be this easy.

Parts came in yesterday so we started putting it back together. The rear most nut and allen screw went on no problem. BUT the more forward nut and screw are right behind the window glass (which makes it worse since you can see where the screw-nut goes) Talk about a PITA...fingers don't fit to get the threads started & using some type of super thin pliers can't feel the threads!!

I found that lifting the door handle will angle it down enough that the allen screw on a "angled" wrench almost works..its really close...but after a three man operation (me on wrench-gerry holding handle up-sara pulling glass back for more room) we still couldn't get it threaded!! I still don't know how I could get the nut on that holds the plate in place...once its on it would be easy to tighten, but getting in on is a real pain!

I'm at a loss! Pulling the window would solve the problem, but thats got to be a total PITA too! Any ideas!!!!
Help

Nicole

Was the window up or down when you tried this? Have you tried both positions?

If that does not give you enough clearance, it's relatively easy to losen the window and just tilt it - maybe that'll give you the clearance you need.

However, you have to be careful to adjust it right when you put it back into position. In my experience, it's best to roll it up and push it into the channel on both front and rear end of the glass, then tighten the nuts.

Hope this helps!

928drvr86.5

put the window down.

928drvr86.5

Or up, i can't remember. I can tell you one way was pretty easy and the other way was next to impossible, just can't remember which.

928drvr86.5

I am thinking down is best, as the rear edge of the window curves forward and is out of the way when the window is all the way down. When the window is up i think the lift mechanism is in the way.

perrys4

Glass goes down. I just did this and it only took an hour and a half being my first time.

DG84S

Replacing the door handle mechanism is a rite of passage for a 928 owner. I find that I now open the door more gently than before. The next time it's replaced will be by the N.O.

IcemanG17

So it appears window down is the next step...thinking about it with curved window that should work...I'll try tomorrow & update (with some pics!)
Thanks

Normy

I'm a slender guy but I have normal sized, strong hands with long fingers. No I don't play guitar, sorry. When I did this job on my '85 S2, I didn't think it was all that bad, but I had three advantages:

1. I've had my door panels off so many times that this is almost a routine job; I know exactly how to take them off and it takes me less than 10 minutes now to pull one. I have about 2/3 of the push-pull clips actually installed and working, so it is easy for me. I'd have them all, but the wood around many of the bottom clips has torn away.

2. My car has the electric central locking; I removed the central locking servo and let it hang on the wire to the interior door handle.

3. I bought a pair of very long nose needle pliers at a bait shop a few years ago. I don't normally fish, but I've been out with friends a few times and let me tell you what: land a snook or a "mudfish" and you are looking at basically a fresh water barracuda. These guys have a set of TEETH! I noticed the tool that these guys had in their tackle box to remove the hooks and bought one. This thing will help you immensely to put the little nuts onto the screws. My pair of needle nose have points about 5 inches long.

Be real damn carefull if you have tinted windows. Roll the window down all the way and leave it there.

Hope this helps-

N!

PS: I recommend a bottle of Corona, or your favorite beer along with some tunes on the local stereo while perfoming this feat of mechanical engineering.

F4GIB

As I understand it, the part is made out of low quality pot metal [probably by some exec's BIL ;-)]. Here's an oppotunity for one of the "Big 3" to take over a market segment. I'd pay 2 or 3 times the Porsche price for a part that would last that much longer. I hate doing stupid, low-tech jobs over and over again.

IcemanG17

[PS: I recommend a bottle of Corona, or your favorite beer along with some tunes on the local stereo while perfoming this feat of mechanical engineering.[/QUOTE]

Normy
Good music is a must, something to break up the kicking and cussing! After its done it will be time for a Corona!!

Ron_H

It IS a rite of passage. You NEED some band aids for afterwards and soap with which to wash your mouth afterwards. It is NOT fun. I need to remove my passenger side because the allen screw that hold it at the trailing edge of the door is stripped so the thing wobbles, and I refuse to even think about that until I win the lottery and have the luxury of wasting the time to do it.

Big Dave

Yep, it's a rite of passage. I do recall having repeatedly moved the window up and down throughout the procedure to get the best access.

The rule of thumb is that if you're stuck, move the window up/down and see if it's easier that way.


Good luck.

IcemanG17

I think the second elbow (mid forearm) and 5 opposing pinky fingers on your hand would help too!

Tomorrow morning-ish the drama will continue!!!

Removing the window would do it......but damm that has to be a pain.....now that I'm thinking about it, the rubber trim on the outside of the window is loose and can be removed providing some more access, but that is only about an inch wide too!

perrys4

Not sure if it will help you with your car, but I followed this writeup and it was fairly easy. Good luck.
http://sis125.berkeley.edu/928/wk-door-handle.html