Door Handle Fix (E53)
Posted: Tue Sep 21, 2010 10:03 pm
Soooo...
Jig’s car developed the door handle failure...
Many thanks in advance to xoutpost for their posts on this – thought I’d also post on this site.
The exterior handle would not open the door (the interior one was fine). Noticed the handle was sitting proud (drivers door) – couldn’t push it down into its normal position.
This is an issue with the door handle carrier. You need to replace it with a new one (perhaps). Part number is 51218243616 for the drivers door or ending in 5 for the passenger one. Rear one’s I didn’t ask about but would assume part numbers will end in 3/4. Roughly coming in at £69 now (Nov 2011).
To get it out, you need to remove this plastic piece, located on the inside of the door sill, next to the handle.
This comes out in two pieces, there is a centre piece that comes out first and then the outer edge.
Addition kindly made by Ubatoid:
This is another view of the location of the screw holding the lock barrel in place.....
Now get the door card off, remove the wood/silver door trim (just pops off – no screws) and you reveal 2 screws and the other two (one behind the airbag cap) and one at the bottom near the cubby hole. TAKE CARE when removing the card - it is still held on by poppers all the way round. When pulling to overcome the release you can pull too hard and break what's already connect inside the door card. You have the VERY delicate plastic piece that feeds the light to the door handle, the door handle cable itself, 3 connectors on the window switch and the light on the bottom edge of the door card. Get these disconnected and the card will come away.
Choice is yours next, take the airbag off or let it hang, bolts as shown. We took it out, remove fuse 44 in the glove box and then unclip it from behind once it’s off. BE CAREFUL at all times and NEVER switch the ignition back on until this is connected back up and the fuse is back in place. Otherwise you’ll get the airbag light on the dash and this can only be reset by the dealer or indy.
Here’s a picture of the carrier in situ once you remove the foam backing, where the side airbag was.
You need to get this out. That first plastic piece on the door sill that was removed will reveal an allen key bolt that needs removing. Look at an angle to find it – pretty obvious.
Removing that bolt allows the exterior lock to be removed.
The whole piece will come away – may be stuck in fast...
Remember how it fits, there’s a hole that the barrel will go into, like a cross (Mogs, where are you when I need a decent shot!)
The barrel needs to be removed to allow this bolt to be undone. You'll see how it pulls down and away - be careful not to let the handle scratch car exterior paint.
The handle is free on one end and now the other end just needs twisting through 90 degrees (anti-clockwise – I think). You want to free theses two teeth
They fit into the carrier here
Addition kindly made by Ubatoid:
This is the position the handle needs to be to dis-engage the lugs. Rotate anti-clockwise and pull straight out. I found when re-fitting, it helped a great deal to push the mechanism from inside the door to aid re-engaging the lugs.
Once the handle is out you can remove the rubber protector and see the screw behind it,that also needs to be removed
The carrier is almost free. It will be lose now and you need to get the cable free. There is a collar and ball joint that need to be pulled away – I used a coat hook bent to shape
This is the carrier out and the where the associated collar and ball joint are
In Jig’s case you can see where the failure is
The piece can be replaced but we decided to try an alternative. This should buy a bit of time...
Seems to hold well and once everything is put back together (reverse of the above) we have a working handle.
Hope this helps...
Jig’s car developed the door handle failure...
Many thanks in advance to xoutpost for their posts on this – thought I’d also post on this site.
The exterior handle would not open the door (the interior one was fine). Noticed the handle was sitting proud (drivers door) – couldn’t push it down into its normal position.
This is an issue with the door handle carrier. You need to replace it with a new one (perhaps). Part number is 51218243616 for the drivers door or ending in 5 for the passenger one. Rear one’s I didn’t ask about but would assume part numbers will end in 3/4. Roughly coming in at £69 now (Nov 2011).
To get it out, you need to remove this plastic piece, located on the inside of the door sill, next to the handle.
This comes out in two pieces, there is a centre piece that comes out first and then the outer edge.
Addition kindly made by Ubatoid:
This is another view of the location of the screw holding the lock barrel in place.....
Now get the door card off, remove the wood/silver door trim (just pops off – no screws) and you reveal 2 screws and the other two (one behind the airbag cap) and one at the bottom near the cubby hole. TAKE CARE when removing the card - it is still held on by poppers all the way round. When pulling to overcome the release you can pull too hard and break what's already connect inside the door card. You have the VERY delicate plastic piece that feeds the light to the door handle, the door handle cable itself, 3 connectors on the window switch and the light on the bottom edge of the door card. Get these disconnected and the card will come away.
Choice is yours next, take the airbag off or let it hang, bolts as shown. We took it out, remove fuse 44 in the glove box and then unclip it from behind once it’s off. BE CAREFUL at all times and NEVER switch the ignition back on until this is connected back up and the fuse is back in place. Otherwise you’ll get the airbag light on the dash and this can only be reset by the dealer or indy.
Here’s a picture of the carrier in situ once you remove the foam backing, where the side airbag was.
You need to get this out. That first plastic piece on the door sill that was removed will reveal an allen key bolt that needs removing. Look at an angle to find it – pretty obvious.
Removing that bolt allows the exterior lock to be removed.
The whole piece will come away – may be stuck in fast...
Remember how it fits, there’s a hole that the barrel will go into, like a cross (Mogs, where are you when I need a decent shot!)
The barrel needs to be removed to allow this bolt to be undone. You'll see how it pulls down and away - be careful not to let the handle scratch car exterior paint.
The handle is free on one end and now the other end just needs twisting through 90 degrees (anti-clockwise – I think). You want to free theses two teeth
They fit into the carrier here
Addition kindly made by Ubatoid:
This is the position the handle needs to be to dis-engage the lugs. Rotate anti-clockwise and pull straight out. I found when re-fitting, it helped a great deal to push the mechanism from inside the door to aid re-engaging the lugs.
Once the handle is out you can remove the rubber protector and see the screw behind it,that also needs to be removed
The carrier is almost free. It will be lose now and you need to get the cable free. There is a collar and ball joint that need to be pulled away – I used a coat hook bent to shape
This is the carrier out and the where the associated collar and ball joint are
In Jig’s case you can see where the failure is
The piece can be replaced but we decided to try an alternative. This should buy a bit of time...
Seems to hold well and once everything is put back together (reverse of the above) we have a working handle.
Hope this helps...
I probably get a new lifter soon it was the thrill of repairing for free for now.
plus my detailers guy been real lazy 
(you know who you are)
.....so any new mods since you last graced us with your pressence ....or any planned