[lbpesq]

I need to replace the driver's side exterior door handle lever. I've searched the Forum and found some very helpful pics and advice. It seems like I will need to order the new lever and the two gaskets that sit between the handle and the body. Is there anything else I'll need to order or should replace as long as I'm doing this? Thanks in advance for any and all suggestions.



Bill

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[Trueblue]

Hello,

There are about 8 pages in the factory Maintenance manual relative to removal and installation of the door handle. If you need a copy of these I can forward them.

<img src="/forum/images/smilies/968/wink.gif" class="smilie" alt="" />

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[SILVY968]

Bill, I have tried and failed replacing the door handle. the lever/clip inside the door is really hard to do. After trying many times I gave it to my PM to do. He took over an hour to get it done and said that he almost gave up. It is difficult to get any tools to the area that you need to get to.

Good luck.

the other thing that you will need is patience...plenty of it.

brian

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[lbpesq]

I called my mechanic. He said he would do it for about $200. While I think I could probably pull it off, it looks suspiciously like an all day job for me. If I spent that day in my office I'd make more than $200. If I spent that day relaxing or playing music, I'd have a lot more fun, so it's off to the shop tomorrow. Thanks for the advice.



By the way, ever since I bought the car last year, the door handles have always required a lot more pressure than any other car I've ever owned. Do others share this experience?



Bill

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[bombfactory]

My door handle levers require a lot of pressure to open the doors as well. Is this typical/normal? Will they get 'lighter' if I do a refresh of the door handle components? Not really looking forward to this particular job!

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[pmason]

I did this just a couple of months ago, very painful, took 2 hours just to get it apart. then spent 2 hours trying to putting it back together and broke the cheap linkage, ordered the new linkage, and still took almost another 2 hours. You need a lot of patience.

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[barth7]

This was my experience as well. And now, a little over a year later, I am about to do the same one again.



Service manual makes it sound so easy. "Attach zee linkage. Place door handle back in zee door." GAHHHH!!!!



<img src="/forum/images/smilies/968/blink.gif" class="smilie" alt="" />

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[AJG]

seem to remeber this subject from before, the advice was to tap the handle towards the rear of the car as it needs to go in that direction for removal.



Andy

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[eurocarnut9xx]

When it comes time to attach 'zee clip', I used a piece of solid wire to pull the lever (in the door with the ball on it) down and held it there with some tape. I also shimmed a screwdriver behind the lever in the door. By doing this, the lever in the door is fixed in position, and applying pressure while trying to seat the socket to it won't deflect it all over the place. I used a wooden handle from a kitchen utensil to apply pressure from the door handle hole with an additional buffer (cardboard), as to not dent, chip, or otherwise damage the door body. I also setup a light source from the bottom portion and vent duct of the door, and I looked in from the small hole in the door handle. It took a lot of force to seat the ball on the socket. Most of the trick was keeping the ball from rotating on the threaded shaft.



While I had the handles off, I gave everything a thorough cleaning and relubed everything. Another lesson learned was to be cautious when replacing the lever on the door handle. The handle is cast aluminum and will crack easily. Be careful when removing the pin that affixes the lever to the handle.



As far as the handle being stiff, one of mine required more force after reinstallation. I believe this was due to the adjustment of the variable lenght connector piece. Rather than taking it all apart again, I loosened the handle using the M5 cap screw on the inside of the door, actuated the door handle, repositioned the entitire handle as it sit on the door, and retightened the screw. This allowed everything the right amount of travel and alleved the excess force being applied by the bits not being aligned correctly.

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[rkeysor]

I've spent untold hours laying on my back looking up through the port trying to slip the nylon piece over the ball. I finally pulled out the nylon piece, enlarged it very slightly with a drill bit, reinstalled the piece in the door and rather easily cammed the nylon piece back over the ball. I then pushed a loop of mild steel wire up in there and safety wired the piece that the part with the ball. It takes very little to maintain the ball/nylon connection. It was quite easy. Cheating. You bet, but it beats the hell out of trying to force the nylon bit over the ball.

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[kenpeterson]

My handle doesn't work. Shop quoted me $350 total to replace the whole assembly, including paint and match new handle. Seeing the amount of heartache this repair seems to entail - I am only a fair mechanic and it looks like the very good mechanics on this board are spending 5 or 6 hours on this fix - I am gonna work overtime Saturday morning and let that pay for the shop repair. The mechanic and I can both do what we are good at and I won't be pulling my hair out and asking myself after hour 7 why I don't sell the thing and get a WRX anyway.. <img src="/forum/images/smilies/968/whine.gif" class="smilie" alt="" /> . Plus I will get a 1 year warranty on the work...

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[Kim]

Ken - I share your sentiment exactly. I was at the bank (fitting, I suppose) and when I came out and pulled the trigger I heard a "snap" and the trigger then was easy to pull. Sadly, the door would no longer open. Fixed at Porsche shop. I worked on the weekend as you will. Money in, money out.

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[Langley968]

I tackle items that I know I can handle and will make me smile while I am doing them AND after. Somethings are best left up to the experts...

Now if I had a hoist...

Someday... <img src="/forum/images/smilies/968/glare.gif" class="smilie" alt="" />

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[Milton-Adamou]

Hi guys,



apologies for hijacking this thread but for some reason my account wont allow me to start a new post, only to reply to existing posts!!??



Anyway, so my driver's door handle finally stopped working. It was getting tighter and tighter, up to the point where pressing it all the way will not release the locking mechanism. The passenger side seems to be going the same way so I need to fix this before I can't even get into my own car! <img src="/forum/images/smilies/968/wink.png" class="smilie" alt="" />



I'm thinking that over time the steel line that goes to the handle has 'expanded' and so pulling the trigger all the way doesn't pull the latch far enough to release. Ideas anyone?



cheers,





milton

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[flwbyu]

My passengers side door handle broke on the inside. Then several days later the drivers door handle on the outside broke. So, if I want to get into my car I have to unlock and open the passenger door. <img src="/forum/images/smilies/968/glare.gif" class="smilie" alt="" />

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[Scott Collins]

Same story here. Just last week the driver's side door trigger snapped as I went to open the door. Now the trigger just floats freely in the handle, so I tied it down with an black elastic hair tie. (Don't go there...) I can either go through the passenger door and open the driver door from the inside, or just go through the window like "Dukes of Hazzard".



Anyway, the question is, what has broken inside the door when this happens? I have seen a couple of different parts offered to repair broken door latches, for instance:



http://www.ebay.com/itm/PORSCHE-924-944-...5644ca8bc7

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[JWahlsten]

Scott,



Sounds like you broke the black nylon connection from the handle to the door latch itself. It is of course the one everyone is complaining about reattaching...



Make sure you measure the length of the rod prior to removing the old one. It will save you a little time on the reinstall. I use a BIG screwdriver to push it back on. Regardless, it isn't fun.



My handles are not hard to actuate, but I lubed them with spray on moly grease prior to reinstalling when I did the gaskets.

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[Scott Collins]

Joel,



Thanks! Any idea on the part # for that black nylon connection?



-Scott

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[JWahlsten]

The part number is 999 168 004 40. It's part number 8

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