Posting as an addition to Drivers door teardown
and Drivers door exterior handle removal
In this post we're gonna remove passenger rear door exterior handle
remove door panel
-remove pull handle trim to expose two phillips screws, one ea top & bottom
- - start at bottom of trim, there is a relief for this purpose
- follow steps from front door tear down to remove perimeter 10mm bolts and 10mm window mount from beneath plastic cap in center of door
- note that for the rear doors you want to tape the window in the fully raised position with painters tape
- I highly encourage removing the door skin rather just the foam service panel. There's a lot to do to remove the exterior handle, and the extra room and line of sight makes things infinitly easier.
- - Drivers door teardown
- remove latch mechanism by removing three phillips screws. There is no other mechanical connection, and the whole mechanism will be free once the three screws are removed. Remove mechanism from door. Note you now have access to the nut & stud holding the latch side to the door, and easier access the the nut & stud holding the hinge side.
- remove nuts from hinge area and latch area, and lift out black plastic support
- remove studs from both hinge and latch of handle, note the short side goes towards the handle
- remove handle from door, favoring latch side first
Here's one method to repair a loose, rattling handle-
What often happens is the return spring retainer breaks off. It's thin and brittle nylon, and if abused by pulling on the handle of a locked door for example, the nylon will crack then break. This allows the spring to rotate and have extra play, which in turn allows the free play of the handle.
The repair can be accomplished two ways: 1) replacement handle, or 2) repair the damaged handle.
Pic showing the return spring retainer about 90% broken off, the crack is clearly visible
Below are some pics of a repaired handle. A small hole was drilled in the closest area of sufficient strength, and then a screw was used for the spring to catch on. A ghetto repair to be sure.The next version I'm going to try a roll pin instead of a screw I think. Or maybe just get another handle....