Door Handle Repair

Just replaced my drivers door handle today. If anyone runs into the problem I did, I hope this helps. Upon removing the door panel (need the special tool you should be able to get at any auto parts store, for the window crank) I proceeded to take off the to bolts holding the door handle on. Easy Right?!?!? Not a chance. My bolts were rusted so bad they started twisting the metal tabs (part of door skin, if broke you'd better be good with a mig welder) so my cure was a drill.

I took a hammer and a 6 inch rachet extension and gave the old door handle a good smack. (after everything else was unhooked of course) and out popped the door handle. Vise Grips weren't helping so I took the smallest drill bit I had and drilled (from outside door) into the knurled nut thats epoxyed into door handle that attaches to the bolt, and kept working up to the drill bit size that is just smaller than the actual bolt. Then with vise grips outside the door on the knurled nut, and a 10 mm socket on the inside, I was able to snap off the rusted bolt. Then I took a trip to the local hardware store and bought some short (approx. 1/4 inch long) metric bolts. Took new handle to make sure of fit. Got home and put ole' girl back together. Good as new.

P.S. With the door panel off it would be a good time to clean ALL debris from inside the door and shoot some wd40 or some oil into bottom of the door to prevent future rust. Sorry for no pics. Makes me want to do the passenger door now for no reason just to show ya. Just my :2cents: hope this helps

For those times when you don't have the special tool available you can use a rag to get the window crank off. Simply place the edge of the rag between the base of the crank and the little plastic circle that goes between it and the door (this puts it against the metal circlip that holds the crank to the shaft). Pull the rag tight by holding opposite ends of the rag and then rotate it around the crank (this is the part where you wish you had three hands). Also you will want to keep tabe on where the circlip goes. But this will get the handle off for you.

you can also take a piece of baling wire and make a small hook in the end of it and use it to catch the loop in the clip and pop it out