Having started to replace the near side front window regulator new panel I found that the previous owner (not my son)had already drilled out the ten panel rivets and two of the four speaker ones.

Not sure why of course unless it was leaking water.

Anyhow once I took the panel off the door and started to remove the wiring to transfer to the new panel, I noticed the lock plastic support bracket was cracked where it was riveted to the lock part so I plastic welded it and It worked out ok.

Then after that I dry fitted the lock panel to the door, but being pretty tight to ease in the door the plastic push fit thingies holding the lock bracket to the new panel came loose so I withdrew the panel and used stainless steel nuts and bolts in place of the 3 original thingies.

all looking good, I re fitted the door pillar 4 electrical plugs and rubber boot again all good but what an difficult part of the job.

That left me to fit the window winder motor and try it out and all good there, nice and smooth as you would expect.

Now to the big issue, when I had the car that door handle was strangely sitting proud at the opening edge from the fixed section when the door was closed and worked ok, on re fitting the moving handle with the cable that pulls the lock catch, I thought it would be an idea to see if the available adjustment would hold the handle more flush which it did, I took several attempts with a screw driver working the lock to the locked position and checking that the handle would actuate the lock and every thing worked perfect.

The locking unlocking worked perfect  with the door in an open position, then to my shock when I closed the door and locked the car on the plip then unlocked it the door would not open, all others did.

So anyone got a solution to this, I haven't riveted the door panel yet but quite shocked it has happened.

Martin 

 

Have you tried opening it from the inside?

Hi Sepulchrave, yes I did.

After lunch I tried it again but it still would not open from the outside then I tried the same side back door just to check that opened which it did the I tried the stuck door again and to my amazement it opened.

So I re adjusted the lock actuating cable back to where it was in the first place but the end of the handle now is proud again by about 4 mm but opens repeatedly thankfully.

Panic over and door panel rivited back and all is good.

I was going to post this up date before I logged in this evening. 

Thanks for your thoughts Sepulchrave. 

Martin

For what I read sounds like you need to locate the pre-load spring in the correct slot. Happened to me and thought it was a stretched cable, inner handle was loose and outside handle rarely worked, until I read the workshop manual about the little spring thingy. Putting it in the right place solved my problem. 

The bad news is, you'll need to re-do everything because relocating the spring is easier with the door lock out. It is possible to do it with the lock installed but you need the right tool and you risk damaging your window since the spring holds quite a bit of tension and snaps easily.

3 hours ago, juanse_2691 said:

For what I read sounds like you need to locate the pre-load spring in the correct slot. Happened to me and thought it was a stretched cable, inner handle was loose and outside handle rarely worked, until I read the workshop manual about the little spring thingy. Putting it in the right place solved my problem. 

The bad news is, you'll need to re-do everything because relocating the spring is easier with the door lock out. It is possible to do it with the lock installed but you need the right tool and you risk damaging your window since the spring holds quite a bit of tension and snaps easily.

Hi juanse-2691, thanks for your info, am not going to re do things at the moment as the door lock works ok, of course my door is the riveted version being a 2006 so not as easy as the bolted on ones.

Martin

Same here, riveted 2007. 

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Edited 3 March, 20215 yr by Guest