[Larry Currie]

<img src="/forum/images/smilies/968/sad.gif" class="smilie" alt="" /> My drivers door will not open from the outside. Any ideas on the problem?

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[doster]

there are a couple of white plastic clips that hold the linkage. If your lucky the

linkage may have popped out or you will have 2 small plastic in the bottom of

your door. I had the same problem and you will have to remove the door panel

to get at it. hope this helps and good luck <img src="/forum/images/smilies/968/smile.gif" class="smilie" alt="" />

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[Darth Vadar]

Odd as this sounds, I had the same thing happen when I accidentally hit the Central Locking console button, and then closed the door...



Try using the key to work the lock a bit(with the door closed) and it may come around! If not, see above post!

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[Larry Currie]

Is there a part that breaks that can cause this? Like maybe the clips. I'd like to order any part that could cause this so I can replace the broken part if needed when I take off the door panel.

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[Ed Russo]

[quote name='Larry Currie' post='30072' date='Jan 21 2007, 08:01 AM']Is there a part that breaks that can cause this? Like maybe the clips. I'd like to order any part that could cause this so I can replace the broken part if needed when I take off the door panel.[/quote]

Larry,

I'm having the same problem. After pulling the outer door handle away from the door,I was able to see the broken part.

Called Sunset Porsche and explained my problem. I asked them to fax me a illustration (#804-05) for my '94 cab. From the illustration I was able to order the parts I needed.

Its hard to believe but the three parts (#46,47,48) only cost under $10. Add the shipping and these are the most resonable parts I have ever bought.



Hope this helps <img src="/forum/images/smilies/968/biggrin.gif" class="smilie" alt="" />



Ed Russo

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[SILVY968]

Ed,

The parts are cheap, especially for this car, but just wait until you try and install them!

Been there, done that. I hate to admit it but I finally had to go to my PM who spend 2 hours relacing the handle, lock and lever to get my door to open from the outside. While I was there I decided to replace all the bits and pieces. I figured that since 1995 it had been well worn. As it turned out the only item that was broken was the linkage rod with the plastic adjuster end on it.

Brian

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[doster]

Its not that hard to do although it is a little tight in there!

If you decide to take the lock out of the door scribe a mark around the plate

so you don't have to guess when you put it back in.



and if you take the lock out use a large phillips or you might strip em, mine were pretty tight



Good luck You can dooo itttt <img src="/forum/images/smilies/968/smile.gif" class="smilie" alt="" />

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[Larry Currie]

So, to do the total job, what parts do I need to order?

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[SILVY968]

Larry,

Here is what I ordered. If you want to replace the handle you will have to paint it first. A great source for rattle can Porsche matching paint is PAINT WORLD 1-800-548-4321 http://paintworldinc.com/



94453766104 outer door handle

94453767100 control lever

94453765500 tension spring

94453724300 clinch pin

94453763700 pin

94453726102 reverse lever ( 99916800440 ball socket should come with it )

Rubber gaskets for the handle where it mounts to the door, if you need are:

94453762100 and 94453763100.

All parts that have a L or R are for LEFT side.



Good Luck with this one. doster is correct, the screw on the inside frame of the door is TIGHT. Be careful not to strip out the handle threads and an impact driver for working on motorcycles comes in handy for tight screws. Complete instructions with pictures is in the workshop manual, from this site, on pages 57-1 thru 57-9



Brian

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[Larry Currie]

Thanks for all the help.

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[Alka111]

Hello,



I'm currently facing the same issue.

Part 46 is broken.

I've ordered #46 and #48.

But it seems no way to take the old pin #48 out of it!

Is it rivetted? Do I have to drill the top of it to remove it?



I guess I've also to remove screw#10?

There is not so much space...then I'm about to remove to central locking panel also, but not sure it will help...



Thanks for advices!



PS: I'm french, please forgive my writting style...

Nico

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[Alka111]

I got it repared today.

A whole afternoon for it.

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[Anchorman]

I thought I'd revive this thread with a tale that hasn't reached its ending yet.

My driver's door was getting harder and harder to open from the outside. Two years ago I knew I'd have to replace some parts so I started accumulating - but kept putting off doing the work because I'd been inside the door some time earlier, working on the lock linkages, and hated it - so I decided I wouldn't do it until I had no choice.

Well, "no choice" finally happened a few weeks ago when the lever broke! So, I decided that today would be the day - and I'd do the whole job, once and for all. The exterior handle retaining screw was also stripped, so I'd obtained a "new" handle - with the link already mounted on it. "All" I needed to do was remove the old handle (pretty easy except for getting the two links disconnected - which is only exceeded by what it takes to get them reconnected!). The lock itself was always a little loose, so I decided to remove it and reinstall with new bolts (from which I'll have removed the Loctite before using - I'll risk them loosening up rather than enduring the difficulty of removal - again, something learned earlier).

So, with the plan in place, the work began. The two bolts for the lock mechanism don't want to come out. I've seated the 5mm Allen wrench firmly (hammered it in to be sure), but despite that, one head is stripped and one is on its way. I'll try an impact wrench before I resort to cutting the heads. I really do hate Loctite!

The exterior handle is off the car, now I need to remove the lock cylinder so that I can mount it in the "new" handle. Of course, I can get the pin out that holds the lock in place - the Porsche instructions make it sound so easy...if only.

Then it turns out that the new lever I have is for the passenger side, not the driver's side. I've sent an email to Jeff at Sunset - hopefully the lever I need is not sitting in Germany. And, as long as I'm purchasing stuff, I'll get new gaskets.

Then there's the "while I'm in there" stuff - which, in this case, means trying to get the window to go up and down more easily. Once everything is done, there's putting the door panel (and all of the associated stuff) back on.

I truly hate this aspect of our cars.

Thanks for "listening".

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[Anchorman]

A little update.

It turns out that once the lock mechanism in the old handle was cleaned, the pin holding the lock in place was visible, and was removed with a paper clip being tapped by a hammer. Wow, what a pleasant surprise.

Sunset is sending the needed lock lever and gaskets, so that'll take care of the parts.

The bolts holding the lock in place on the door would not budge, even with an impact wrench. So, hopefully leaving this with it able to have some slight movement will not be a fatal flaw. I really don't want to cut the heads off and then try to figure out how to get the bolt stubs out.

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[Anchorman]

This project is creeping towards a conclusion. The needed parts arrived from Sunset (kudos to Jeff!) so the installation of the new lever in the replacement handle was the next thing to do. The only part I needed from the old handle was the lever tensioning spring. The instructions in the Porsche repair manual say that the rivet holding the handle and spring in place should be cut with a hacksaw - easier said than done. Given that I didn't need the handle, I used a somewhat more brutish approach to get the spring out, which involved breaking the mounting studs on the handle.

The next step wasn't as bad as I though it would be - getting the lever and spring positioned in the "new" handle so that the new rivet could be inserted. However, the manual step that describes "Reestablish rivet connection" talks about enlarging the rivet head. There was no way I could get that to happen - so (and this is what I'm up to right now) I've inserted the rivet so that the head is up (gravity won't remove it) and I'm going to put some type of adhesive on both ends of the rivet and hope that the assembly stays together - at least for the rest of the time I own this car.

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[flash]

you can't put in a new rivet?

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[Anchorman]

I have a new rivet inserted. What's challenging is spreading the end so that it locks in place. The Porsche instructions say: "Position drift in a vise. Place preassembled door outer handle with rivet stud area (flat side of the rivet stud) onto the drift...enlarge rivet stud using a center punch."

As an old song says, "Easier said than done."

I may try to find a machine shop in my area that can attempt this - but only because I haven't found my tube of Crazy Glue yet.

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[Anchorman]

I found the Super Glue before looking for a machine shop - so the deed is done. The rivet is glued in, the lock is reinstalled (the pin that holds it in place took a lot more effort to get in than it took to remove - lucky for me), and the entire handle mechanism is now ready for going back onto the door. It's raining so I can try that today, but maybe tomorrow. Will I ever be glad to have this behind me.

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[Anchorman]

The handle is installed, the links are connected, and everything works. Whew, what a relief. Now it's down to merely reassembling the door interior panel - also not fun, but much easier than what I've already done. Maybe I'll get inspired to do the instrument panel work that's needed, and that also has been waiting for more than a year.

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[SILVY968]

The door handle linkage has got to be one of the simplest sounding, yet most difficult and frustrating jobs on the car!
Been there gave up on that.
My PM took 1.5 hrs to finally get the handle linkage hooked up!
He was not happy when I picked up the car.

The instrument cluster is a breeze by comparison.
Brian

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