924Board.org

numbbers · Posted: Wed Jun 16, 2004 9:13 am Post subject: Replacing Door Handles

I am about to replace my outer door handles with a set in better condition. I read the Haynes, and it does not reference removing the door panel. Has anybody removed and reinstalled the door handles without removing the door panel?
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1980 924 Turbo

gohim · Joined: 02 Nov 2002 Posts: 4459 Location: Rialto, CA

The door handles changed from the early style to the late style part way through the 1980 model year.

Either way, you don't have to remove the interior door panel to replace the door handle, but the early door handles are easier to install.

The early and late door handles cannot be swapped back and forth. If you have early handles, you gotta stick with them and visa versa. The dock latch mechanism and the lock pin in the door jam changed at the same time.

Chrenan · Joined: 15 Jan 2003 Posts: 3903 Location: Canada

I have a late 1980 model and when I replaced my door handles, I removed the interior door panels. How else do you connect the door handle to the trigger mechanisms to open the door and lock the door?
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1987 951 - M193 Version for Japan

gohim · Joined: 02 Nov 2002 Posts: 4459 Location: Rialto, CA

To replace the door handle without removing the panel, you have to reach in through the larger hole in the door (where the handle mechanism fits through the door) with a tool/s (I used a pair of screwdrivers & "long pattern" 15" needle nose pliers) to grab the linkage from inside the door, manipulate the linkage into place, and snap the plastic connectors on.

Kragen Auto Parts (Parts America) carries a set of five "long pattern" needle nose pliers (straight, 45 degree tip, 90 degree tip, round jaws, & smooth jaw I think) that was on sale with rebate last Xmas for $8. I think the regular price was only about $16-$20. Made in China, but nice quality, lifetime warranty, and much cheaper than the similar tools from Sears (about $25 each tool from Sears).

Chrenan · Joined: 15 Jan 2003 Posts: 3903 Location: Canada

Gohim,

That is definitely one way to go, but removing the interior door panels is pretty simple, and then I was able to disconnect and reconnect everything related to the door handle by hand....

Chrenan
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1987 951 - M193 Version for Japan

gohim · Joined: 02 Nov 2002 Posts: 4459 Location: Rialto, CA

Access to the door handle linakges is not imroved that much by removing the interior door panel, and when you go in through the interior panel, you have to disturb/cut/open the plastic sheet that seals the door interior from the cardboard backed interior door panel. The door panels are easily damaged by moisture (ever note the number of water damaged interior door panels?) when the sealing sheet is not restored after opening it up.

When I had my 77 924, I replaced the door handles, and tried to reattach the linkages by going in through the interior panels. When I was done, I didn't think it was any easier to do it that way.

To each his own, whatever works for you...

Chrenan · Joined: 15 Jan 2003 Posts: 3903 Location: Canada

Yep, to each there own. That is a good point about the sealing plastic inside the door panels. On mine it had been removed before I got in there, so I replaced it on my way out, so it was kind of a 2 birds with 1 stone situation...
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1987 951 - M193 Version for Japan

numbbers · Posted: Sat Jun 19, 2004 11:21 am Post subject:

Well, I finished replacing the early '80 924 door handles with some from a 944. The difference is in the cams and the push rods. However, it is very easy to change the cams and rods, by removing the roll pins.
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1980 924 Turbo