Re: door handle tips

["Chris Bishop" <crash70@epix.net>]

> Yeah, I'm an Audi neophyte... it's my first door handle...
--snip--

....and it won't be your last!

As far as replacement, I usually remove the door panel, and the locking
mechanism from the door. I've also replaced Audi door handles by just
removing the old handle, and snapping the rod ends on the balls on the new
handle. Try it first without removing the panel. If it is just too much,
you can always fire off the panel to ease the process. Either way, obtain
some major-league patience, some little pick-tools and bent pieces of
metal, and possibly a friend. 

When removing the old handle, put some butyl (from your last taillight lens
change, of course) on the tip of a #3 screwdriver to keep the screws from
dropping down inside the door. If you are attempting handle replacement
without door panel removal (it can be done) it can be really
annoying.removing the door panel just to fetch a screw.  

Before you install the new handle, make sure the latch mechanism on the
handle is fully lubricated. (this is one of the major reasons these handles
fail) Pot metal against pot metal is amazingly abrasive.

Also, when you pop off the rod ends, be sure to unclip the little tiny hasp
that folds over the tip of the rod end. (they resemble shift rod links
found on VWs, if you're familiar with them) Be really careful not to break
the hasp, since the ball will not stay in the socket very well without
them.

A final tip to long-living door handles. When you open the door, push IN on
the door BEFORE squeezing the lever on the handle; this helps to take the
pressure off the plate that latches over the locking pin. You'll instantly
notice how easy it is to squeeze the handle when you open the doors in this
manner. This low force requirement also equals less wear on the handle.

Hope this helps you out,


Chris Bishop

Team Door Handle, Inc