[968gene]

I didn't want to cut the gaskets. I was concered that the gaskets would "walk" from under the door handles with use. Not a bad DIY. The results are worth the time invested.

DIY, Door Handle Gasket Replacement (and Door Panel Removal).pdf Size: 1.14 MB  Downloads: 238

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[Anchorman]

For those that haven't done this, the "cutting" technique has little of the risk that 968gene is properly concerned about. The gasket that requires the surgery - the large one - has rubber "pegs" that locate it in the proper position between the door body and the handle. Therefore, it can't "walk" very far. The difference between doing the replacement with the cut, and proper replacement, is: the "cut" only requires removing one bolt, the one holding the door handle in place. The "proper" replacement requires doing that, plus removing the door handle electrical connector and the two mechanical links so the the handle can be completely separated from the car. This dismantling can be done through the handle area and the door vent opening. However, in my repeated experiences, reconnection of the links (actually, just one of them) can only be done with the interior door panel removed. Not a major job, but if I was just needing to replace the gasket, I'd do the "cut" technique.

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[Greimann]

I fixed your PDF Gene and uploaded into your original post. Good work!

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[968gene]

Thanks Dave, can you delete the first try (blank post).

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[Anchorman]

Nice job, Gene - but, with no disrespect intended, I think it doesn't go far enough and misses the most difficult part of the job - the reassembly. Reconnecting the two actuating rods was no small challenge. When I did the disassembly, I removed the little white plastic piece from the lug on the handle mechanism, as I found that's the easier connection to redo for assembly. The black plastic piece at the end of the actuating rod is the biggest challenge. I managed that by using my right hand (working on the passenger door, as you show) to reach up through the ventilation opening and position the opening on that piece against the metal lug on the lock actuator. With my left hand, I carefully fed a large flat screwdriver through the little square hole in the door until the blade was near my right hand. Then, after my right hand positioned the blade against the plastic piece, I pushed the screwderiver handle towards the front of the car, snapping the plastic piece in place. This generally took a couple of tries, but worked. The repair manual suggests reaching these pieces with a pair of pliers through the ventilation opening and squeezing them together, but I found that to be impossible.

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[NeedPorscheSpeed]

Excellent job, Gene! I will be tackling this job in the near future, and this is the best write-up that I have found. A+++ Work! <img src="/forum/images/smilies/968/smile.gif" class="smilie" alt="" />

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[968gene]

Thanks, you may also want to source a pair of long needle-nosed pliers to snap the rods back onto the actuators.

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[Anchorman]

The pliers approach is what the manual recommends, but I've never been able to get that to work. As I described, I've been successful with the flat screwdriver method.

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[NeedPorscheSpeed]

[quote name='968gene' date='Mar 31 2005, 01:27 AM']Thanks, you may also want to source a pair of long needle-nosed pliers to snap the rods back onto the actuators.

[right][post="2630"]<{POST_SNAPBACK}>[/post][/right][/quote]



Thanks, I'll keep that in mind, as well as the flat screwdriver method that Anchorman recommends.



Gene, I see that you picked up that lovely low mileage cabriolet that was on eBay last fall. It was only 50 miles away from me, and I almost went to take a look at it. Fine car you have there! <img src="/forum/images/smilies/968/smile.gif" class="smilie" alt="" />

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[SANDOVAL]

VERY well done, thanks for all the great info and photos!!! These DIY instructions are going to be such an asset over time.





Thanks!

Eric

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