Gasket replacement on exterior door handle
05-18-2014, 09:04 PM
#1
Track Day
Thread Starter
Gasket replacement on exterior door handle
The rubber gasket between the drivers side door and the door handle cracked and part of it has broken away. I'm trying to figure out how to disassemble the handle to replace the gasket. I looked at P-car and didn't see anything there so any help here would be appreciated. Thanks.
05-18-2014, 11:25 PM
#5
Burning Brakes
Originally Posted by pezza
Ok,
Here is how I done it as I have had several emails asking. It is pretty straight forward, infact easier than the 968.
Use the DIY step by step guide to remove the inner door panel mentioned in the post earlier, you do not need to remove the top section of the door panel (the part with the mirror switch and LED in.)
Then carefully peel back the plastic door membrane, try not to tear it, once this is peeled back, (you don't have to completely remove it, just give yourself enough room around the access panel.) you will be able to see the back of the door handle. It is secured with two nuts, sorry can't remember the size.
Before you undo the nuts, you need to remove the black plastic cover that goes over the lock mechanism, this is held in place by two small crosshead screws that you undo from the back of the door shut.
Once the cover has been removed you can access the two nuts, simply undo the two nuts and the whole handle will pull out with the lock mechanism attached. While you have the handle off grease up the moving parts, and clean around the mounting holes on the outer door skin, replace the rubber gaskets and refit. The job took about 45minutes.
Have fun!
Here is how I done it as I have had several emails asking. It is pretty straight forward, infact easier than the 968.
Use the DIY step by step guide to remove the inner door panel mentioned in the post earlier, you do not need to remove the top section of the door panel (the part with the mirror switch and LED in.)
Then carefully peel back the plastic door membrane, try not to tear it, once this is peeled back, (you don't have to completely remove it, just give yourself enough room around the access panel.) you will be able to see the back of the door handle. It is secured with two nuts, sorry can't remember the size.
Before you undo the nuts, you need to remove the black plastic cover that goes over the lock mechanism, this is held in place by two small crosshead screws that you undo from the back of the door shut.
Once the cover has been removed you can access the two nuts, simply undo the two nuts and the whole handle will pull out with the lock mechanism attached. While you have the handle off grease up the moving parts, and clean around the mounting holes on the outer door skin, replace the rubber gaskets and refit. The job took about 45minutes.
Have fun!
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Gjbacci (11-03-2022)
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05-22-2014, 10:11 PM
#8
While you're in there.... And the door handles are off the door, clean out the door opening mechanism in the handle and re-lube. I used brake clean and let it dry out. I used a light synthetic grease. You can run into problems with the locks if the spring and plunger get gunked up.
05-23-2014, 07:54 AM
#9
Rennlist Member
Ironically, I just replaced mine last weekend after dreading it for more than three months...not as bad as I expected and took about an hour and a half. Used PB Blaster on the door handle nuts in the inside of the door, only peeled back the plastic sheet under interior panel enough to get where I need and everything went back as expected, nice and tight.
Might have helped to already been comfortable taking the interior panels off prior to do a speaker swap on my Hi-Fi..
Little flashlights, little spanners and patience go a long way.
Might have helped to already been comfortable taking the interior panels off prior to do a speaker swap on my Hi-Fi..
Little flashlights, little spanners and patience go a long way.
05-30-2014, 12:16 PM
#10
Ironically, I just replaced mine last weekend after dreading it for more than three months...not as bad as I expected and took about an hour and a half. Used PB Blaster on the door handle nuts in the inside of the door, only peeled back the plastic sheet under interior panel enough to get where I need and everything went back as expected, nice and tight.
Might have helped to already been comfortable taking the interior panels off prior to do a speaker swap on my Hi-Fi..
Little flashlights, little spanners and patience go a long way.
Might have helped to already been comfortable taking the interior panels off prior to do a speaker swap on my Hi-Fi..
Little flashlights, little spanners and patience go a long way.
When I saw the tight space around the "front" nut, I almost gave up. The secret was to remove a plastic panel that made it very tight in this area (#19 in the part diagram). The DIY did not mention it but it was just the removal of two very small Philips screws that are accessible on the outside of the door. Than the piece could be fiddled out to provide better access.
It is still tight and you need to be PATIENT to not mess up and / or drop this nut. Most of the time, I worked on this without vision but you get used to it quickly.
When I had everything out, I cleaned the threads on the handle thoroughly and worked the nut up and down until I could move most of it with my hands. This was critical to get them on easily in tight space.
In total, it took me about 2 hours but I took my time to avoid costly mistakes. I will have a Paulaner tonight!
05-30-2014, 06:24 PM
#12
08-22-2019, 08:39 PM
#15
Rennlist Member
