[Langley968]

[quote name='Scott Collins' timestamp='1365564044' post='141192']

New gaskets can be installed without removing the door panel, but you have to be willing to cut the gasket. I cut it in the center of the short straight section of the gasket.

[/quote]



Just did that procedure tonight. Thirty minutes to do both sides, including removing old gunk behind decomposed gaskets.

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[KRAG50]

How do you loosen the door handle enough to slide the gasket out then the new in?

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[tamathumper]

IIRC, you loosen the big screw on the back side of the door (e.g. the side where the latch and stickers are), and the handle moves forward and out.

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[DaveN]

You have to cut one gasket as well unless your keen on removing the whole door handle which is NOT recommended; something about sanity.

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[Scott Collins]

just make a clean snip in the gasket. no problems from what I have seen after about 2 years, and I have checked inside each door since doing it. No signs of any water leakage.

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[KRAG50]

Thanks guys

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[unknown4u]

I did last year the same, but I did not cut the gasket, Because it is rubber it can stretch a little. It stretches enough to mount it.

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[Scott Collins]

unknown4u - Good point! I didn't even think to try to pull it over the handle, figuring it would just rip.



By the way, I mentioned earlier that there was no tensioning spring on the clinch pin when I removed the handle. My buddy Stephan, who was helping with the job, thought he saw one when we took it off, and that maybe one of our combined 5 children who were playing around the car might have taken it.



Anyway, he came up with an interesting solution to this problem. I'll post a pic when I can get it loaded. It's pretty "snappy".

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[Scott Collins]

Here's the solution to not having the spring.

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[gbarrier]

Get a cat.

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[hot968]

This sounds great I am going to tryit without taking the door panels off- So much easier, I hate taking the door panels off I did that once and I still have a air comming in sounds when driving now.

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[hot968]

Did the door handles gasket today and it went very smooth. I did not take the door panels off and was able to strech the gasket over the handle with a little help from blow dryer heat. Came out great. Thanks for the great help from the forum.

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[Scott Collins]

OK - so I previously thought that the removal and install of the heat shield was the worst job ever on the 968. But I was wrong. Even though there are lots or worthy candidates for "worst 968 job", as of now, the door handle replacement is the new #1 "Worst 968 Job". It's not a dirty one, like replacing c/v joints. No, it's just frustrating!!!!!!



I can't figure out how to get it back together without 4 hands. And even if I had that, human wrists and fingers don't bend in the way they need to bend to get up inside the door. Seriously thinking about removing the window/window guide so I can see the connections and get to them.



Anyone have any bright ideas? Thanks.



-Scott

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[mbardeen]

Flash had a neat trick to get the socket on the ball that I've now used a couple times with good success. If you look, there's a bit of a slot in the black plastic socket. If you put a screwdriver in there and twist a bit, it will open the socket just enough to slide on the ball smoothly (or at least, with much less effort than previously).

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[Scott Collins]

Cool -I'll give that a try later. Thanks.



How's everything going with the only 968 in Chile?

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[flash]

mbardeen - lol - yup - i mentioned that in another thread a week or two ago.

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[wingers]

Fitted new drivers lever to the door handle today, one tip is to use a heat gun gentley on the area of the white plastic ball socket doing this one first, the black one last snapping on with finger and thumb.

 

Fitting up the door panel to-morrow, been apart for two weeks  while parts came have two curved brackets with self tapping clips in them can't remember where they bolt on?

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[williamoss]

It is funny that you mention the need for punches. In 1979 I had a 924 that I did not want to drive in the winter. So I bought a Toyota with a blown engine, as it required a total rebuild. So I went to Sears and made some salesman very happy since I spent about $1,000 on every tool I saw to rebuild the engine. Over the years all these tools have been used for all sorts of jobs. Not only auto work. as I was a contractor for 27 years. My point is having a good solid set of tools always make all jobs easier.

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