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Re: 1996 passat r6 glx door handles wont open
After paying the dealer $135 to replace the first handle that stopped working, I found out on my own that this is an easy fix that doesn't require replacing the handles. The reason the handles aren't working is that there is a small brass roll pin that has slipped out of the internal mechanism. Each handle can be quickly removed by unscrewing the large phillips-head screw found just above the door latch. Once the screw is removed the handle is held in only by a metal clip that will release with a firm pull. If you are lucky, the roll pin will have only slid out of place and will still be inside the handle. You can push it back into place and the handle will work like new. If the roll pin is gone, you'll have to find a suitable replacement. Check your local hardware store. Most likely they won't have brass but they should have a steel pin the right size. If you find and use the original pin, I suggest you GENTLY expand it a bit before you push it back in. Remember, the part of the handle the pin goes into will split if you force in a pin that is too large. You also might want to lube the spring mechanism with some silicone spray before you replace the handle.
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