Fix outer door handle (Sharan/Alhambra)

[dreddfan]

The outer door handle on the passenger door of my 2006 Sharan wasn't working so after removing the door card I discovered that the hook that operates the lock release lever had snapped.
I decided to have a go at fixing it rather than getting a new one (coz I like bodging stuff )

First remove the door card:

• Unclip the rubber connection piece in the inner door handle by pressing down from the top with a screwdriver and levering it out of the handle
• Prise out the window control panel, unplug the electrical connection.
• Remove the two bolts/screws holding the door card to the door panel.
• Remove the door card from the door panel by lifting it straight up from the ground to release the yellow clips (this might take some force as there is a bit of glue on the top)
• I didn't disconnect the inner handle, support the door card as this can be damaged if stretched.
• Gently peel the inner sound barrier away from the top corner to reveal the handle mechanism to see whats broken.

Removing the outer handle:

• remove the TX 30 screw from the side of the door (there might be a plastic cover over it)
• Pull the whole handle assembly towards the rear of the car.
• Pull the handle assembly out of the door.

The Fix:

• The hook mechanism was broken in my case: broken hook 1.jpg
• Make a new hook from some steel plate measuring 10mm X 10mm X 10mm and bend it as the red line in the pic. I had originally made it 90 degrees but this didn't pull the lever enough to release the mechanism (the next pic is of the first attempt): hook.jpg
• After drilling a few holes in the hook and one in the remaining bit of the plastic hook to allow the putty to grip both parts, put the new hook in place and secure with a blob of putty. Make sure to pull the handle mechanism to ensure the putty wont clog the slide. repair 1.jpg
• Allow the putty to harden completely and refit into the door panel. This can be tricky as it's hard to get the new hook to engage with the lever (arrowed) but i got it in with a few screwdrivers.door lever.jpg
• Refit the handle with the TX 30 screw.
• Test the door opening and if happy refit the door card, window electrics and rubber connection piece.

Be gentle with the handle for a few days until the putty has gone rock hard.

Enjoy the simple pleasure of being able to enter your vehicle.

MS