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CATOMITE
30-03-2008, 08:16 PM
How difficult is it to change the outside door handles on a 1995 Passatt variant? the drivers one on mine has worn out and will not bleedingwell let me in!. any instructions would be great - thanks

Foringo
23-04-2008, 11:23 PM
I've just repaired the door handles on my '95 Passat Estate. They were getting difficult to open & needed a firm yank! Pins had moved out of position so simply reset them and locked them in with a home made 'C' clip (or should that be a 'G' clip) made from a couple of standard pop rivet stems (these fitted snuggly inside roll pin). Anyway both now work really well again. Took about an hour or so to do both & was very straightforward. Took the opportunity to grease everything up including electric window winder quadrant before refitting door panel. If you need any further info just ask.

http://i285.photobucket.com/albums/l...1/DSC00013.jpg (http://i285.photobucket.com/albums/ll50/Foringo1/DSC00013.jpg)


http://i285.photobucket.com/albums/l...1/DSC00014.jpg (http://i285.photobucket.com/albums/ll50/Foringo1/DSC00014.jpg)

erico
25-04-2008, 12:19 PM
I've just repaired the door handles on my '95 Passat Estate. They were getting difficult to open & needed a firm yank! Pins had moved out of position so simply reset them and locked them in with a home made 'C' clip (or should that be a 'G' clip) made from a couple of standard pop rivet stems (these fitted snuggly inside roll pin). Anyway both now work really well again. Took about an hour or so to do both & was very straightforward. Took the opportunity to grease everything up including electric window winder quadrant before refitting door panel. If you need any further info just ask.

http://i285.photobucket.com/albums/l...1/DSC00013.jpg (http://i285.photobucket.com/albums/ll50/Foringo1/DSC00013.jpg)


http://i285.photobucket.com/albums/l...1/DSC00014.jpg (http://i285.photobucket.com/albums/ll50/Foringo1/DSC00014.jpg)

Nice fix. I went to the junkyard and bought a coupe of handles and put the lock cylinders from the old one in and replaced them in the car. Your repair was simpler with far less hassle than mine was. :D

Camaro91boy
27-04-2008, 05:06 AM
o.k ill sound dumb but how do you get the panels off with out breaking them? my passenger back door dose same as first post it just wont open. inside handle is broke but will open door. so how do i get it off?

erico
27-04-2008, 01:32 PM
Outside Door handle removal

There is a large phillips screw on the side of the door where the lock matches with the car's latch bolt. Unscrew the phillips screw. On opposite door sides ,one side is left-hand threaded screw and the other is a right-hand threaded screw.

That means if you try to remove it and it seems to not want to come out, don't try to force it!! ...try turning the screwdriver in the other direction.

Once you have removed the screw, slide the handle towards the front of the car and it will pivot out from the rear for removal.

The rear ones are less of a pain than the front handles as they have no locks to hassle with. :)

BTW don't lose the screws...they are hard to come by.

Inside Door Panel Removal

Remove all of the Phillips screws (@6-8) holding panel to door. gently pry loose inside door handle mount cover and place it somewhere safe. undo the two large phillips screws inside the handle. From the bottom raise the door panel to uncouple it from the lower plastic latches and then gently remove it from the door. That should pretty much cover removal of the door panel.

Here is a link to an image of the door lock installation (http://img176.imageshack.us/my.php?image=v580334en0.gif) from my Bentley manual.

I hope this helps you sort out your problem.
Cheers,
Eric

Foringo
27-04-2008, 11:29 PM
A little more info....Front door panels are fairly easy to remove (mine has electric windows...winders may be a bit more fiddly)

http://i285.photobucket.com/albums/ll50/Foringo1/DSC00010-1.jpg

http://i285.photobucket.com/albums/ll50/Foringo1/DSC00009.jpg

1) Prise off triangular black plastic cover on opposite side to mirror (may break lugs in process but you may be able to refitting later.....no-nails or silicon?:D)
2) Pull off mirror square adjuster knob
3) Prise off (carefully) plastic door handle outer cover withdraw slightly and unplug switches
4) Withdraw handle from remote control lever move lever about to thread it thru'
5) Unscrew door button
6) Unscrew Phillips screws on both sides of door panel
7) Unscrew two large Phillips screws that are in recessed holes in handle moulding (screws can be left in until panel is removed).
8) Pull door panel away from top window rubber channel a few inches and lower panel will tend to pivot on lower fixings & remove upwards (slide-off top plastic button plate before it gets lost). Watch out that you don’t lose the two screws in the handle.
9) There is a foam plastic membrane which can be carefully removed. First remove speaker (three screws), remove plastic clips by punching plastic pins thru (these can be retrieved later and reused or small self tapping screws can be used. Note the type and positions of these clips because they are of different types. Slid-back remote control lever assembly and remove (unhook link). Carefully peel the membrane away from the door trying not to tear it.

Reassembly is the reverse sequence.

I would assume rear door would be much the same.......

Hope this helps

Crasher
27-04-2008, 11:43 PM
The rebuild kits (that will cure most problems) are only 5 a side. The other problem is the roll pin for the trigger finger sliding out, that is free to fix, just push it back in with a dab of thread lock.

Camaro91boy
29-04-2008, 05:21 AM
thanks alot guys i have to say this is the first car forum where people actually help others out. but thats probably due to the fact most of you aren't like the other american snobs who care only about themselves and their own pride. im going to like this forum alot thans again. i only hope i can be as helpful when one of you all need help.

:beerchug:

Foringo
29-04-2008, 06:04 PM
I think somebody must have broken a side window at some stage in my car's history as there was some glass inside the door but no sign of any damage. The membrane had been cut through...I suspect that was done by Autoglass when they fitted a new one. I went to my local council recycling centre at the weekend and slammed the driver's door with the window wound down which dislodged the glass out of its tracks. It jambed when I tried to wind it up. Got home and managed to reset it without any problems. I don't think that there was a fault with the car..guides etc looked ok...probably just shouldn't have shut the door with it down?