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Old 09-15-2019, 10:34 PM
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gp1200x
gp1200x is offline
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Default Re: exterior door handle removal

I replaced the passenger door handle today since I put on a used door - deer took out my original door.

Some tips:

The bolt does need a 4MM allen key to remove. I used ones with a ball type end since the hole in the door does NOT line up directly with the screw head so the allen key must go in at an upwards angle and slightly towards the front of the door.

My passenger side used a STANDARD Right hand thread screw which is NOT what the manual side.....so it is unscrewed by turning it counter-clockwise.

I drilled the sheet metal hole larger and oblonged the hole upwards since I saw no ill effect in doing so. It allowed me to see the allen key going into the screw head through that same hole with a strong light.

The screw is magnetic so if it is pulled completely out and dropped you may be able to retrieve it with an expanding magnetic tool. If not the inside door cover is not really that hard to take off. You can remove it in less than 5 minutes once it do it a couple of times. Taking the door handle off takes quite a while sometimes even if you have done it. Finding that screw head is sometimes difficult and don't strip the head! Mine was actually hard to unscrew (looks like it had medium strength blue loctite on it) and I was using an allen key with a socket driver on the end. Be careful and make sure that allen key is fully seated and keep inward pressure on it to avoid rounding the head although it appears to be grade 8.8!
 

Last edited by gp1200x; 09-15-2019 at 10:37 PM.
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