crap, I broke my handle (FIXED!!)

[RCA1186]

So I broke my door handle today. I went to open my door from the outside and I hear a pop noise and then the handle was loose and non-functional. It still springs back when you let it go but will not operate the door. Does anyone know if the door handle fix in the sticky will fix it? Or if I might be able to repair it? Or where I can get a bronze-mist painted drivers side door handle haha


EDIT*

I got into my door today, so here is the how to posted later in this thread, but with some pictures and video. I did it slightly different than stated below but with the same results; a working door handle.

Dec 3, 2009 6:12:54 GMT -6 lbiggers said:

This is a fairly easy fix. The '97-'99 models use a plastic lever to activate the unlock mechanism. Remove the door handle. Notice the small plastic arm has the last about 9mm broken off. Drill a small hole in the middle of the break perpendicular to the metal shaft and through the shaft. I use a one inch wood screw to thread into the hole. Cut of the head of the screw when it is in place. Use epoxy and a wire nut to thread onto the top of the cut off part of the wood screw. I have done this on two different cars and so far so good. It may be necessary to slightly bend the linkage rod to achieve the correct play in the mechanism.

heres the link to the video for the repair:


www.youtube.com/watch?v=t4BVTZv6fG4&feature=channel_video_title



the repair



access holes:



the 10mm bolt:

[lbiggers]

This is a fairly easy fix. The '97-'99 models use a plastic lever to activate the unlock mechanism. Remove the door handle. Notice the small plastic arm has the last about 9mm broken off. Drill a small hole in the middle of the break perpendicular to the metal shaft and through the shaft. I use a one inch wood screw to thread into the hole. Cut of the head of the screw when it is in place. Use epoxy and a wire nut to thread onto the top of the cut off part of the wood screw. I have done this on two different cars and so far so good. It may be necessary to slightly bend the linkage rod to achieve the correct play in the mechanism.

[RCA1186]

Hmmmm I'll have to give it a try tomorrow when I have the time. Thanks

[solidraiden223]

I used a Handle off a 97 Grand Prix Four door... Had to Make my own Open Rod But the Grand Prix one fits well

[RCA1186]

Biggers, with the handle off of the door this fix makes a HELL of a lot more sense haha this is a VERY poor design by GM (having the stress of repeated opening of the door put soley on what I like to call "a tiny plastic nub") I'm going to try your fix now might I say, it is quite genius. I'll keep you guys posted on results

[RCSRGREAT]

mine is still broke... its been almost a year like this lol... just never got to fix it, was just looking for a new handle to replace it..

[RCA1186]

Sticky!!! Haha it worked like a charm! I can't thank you enough!!

[fox24racing]

+1 for this fix. I just used a small screw with a big nut around it. Works perfect.

[XJSman89]

Stickied. The next person to do this should grab a couple pictures! Are we sure it will only work for 97-99 models or does it work for 95 and 96 models also?

[RCA1186]

Yeah, you can get clever and really use anything that will work to engage the piece in place of the plastic knub that broke off, I ended up bending the metal rod a little too to make it like new. I'm not sure on the model years it will work for though

[lbiggers]

'95 and '96 have a much different and more durable mechanism. I have never had a problem with the door handle on my '96. I did have to repair both my '98 and '99.

[ijroorda]

I wish this thread had been here a month earlier! My door handle broke right before Thanksgiving and I ended up ordering a replacement off of RockAuto - Dorman P/N 79101 for about $30. It came unpainted; my Aurora is black and my paint is not in great shape anyway so I just used Krylon Fusion gloss black to paint it with a few coats of Krylon clear on top of it. It doesn't match exactly but it looks about as good as the paint on the rest of the car.

I couldn't figure out a good way to fix it quickly at the time, although now that I read this it makes sense. If someone who has done this fix could post some pictures, that would help me visualize it a lot better. I anticipate having to fix my front passenger door handle eventually so I'll definitely give this a try when that day comes.

[lanceslambos]

this is why i don't force my way into my car when its icy. not that you did, but just don't want to break the plastic door handles

[RCA1186]

Exactly haha although mine broke when it wasn't icy. I still cringe when I try and open it in the snow, I also try and pull by the door as well when it is icy. I think mine broke from me pulling too hard in haste as I was in a hurry.

[bobsblue95]

Jan 17, 2010 4:15:11 GMT -6 RCA1186 said:

I think mine broke from me pulling too hard in haste as I was in a hurry.

yeah... somehow they "know" when you're in a hurry and "choose" the worst possible times to fail. It's almost like a bad Stephen King script: "Passive Aggressive Overdrive" lol

[Jae Dee]

I dunno if you guys mean the area behind the handle breaks or the actual piece you grab onto but in the DSM world we had a guy who actually went in and made a fix for the actual piece you grab.
www.rcaz.com/rcaz/sub%20indexes/doorhandlefix/index.htm

its kind of a neat idea you can go through the pics at the bottom to see what he did. My door handle broke on the passenger side and I have a spare but I was thinking about making some of these inserts cause I noticed they are plastic through and through....

[RCA1186]

made a short video and took a few pics, look at the first post

[beastboy1976]

Thanks that will come in handy for future reference.

[sall]

Jan 20, 2010 16:42:21 GMT -6 Jae Dee said:

I dunno if you guys mean the area behind the handle breaks or the actual piece you grab onto but in the DSM world we had a guy who actually went in and made a fix for the actual piece you grab.
www.rcaz.com/rcaz/sub%20indexes/doorhandlefix/index.htm

its kind of a neat idea you can go through the pics at the bottom to see what he did. My door handle broke on the passenger side and I have a spare but I was thinking about making some of these inserts cause I noticed they are plastic through and through....

Dave is awesome guy. I have communicated with him via email and other forums. Very crafty and knowledgeable dude for sure.

I did this today on the '98. Driver door inop since purchase. Would have done it immediately had this been a daily driver. Anyways, did both front doors. Driver door definitely busted, passenger door was feeling off. Turns out the passenger door was not broken it was just rusty and needed some penetrating oil and lube. Works perfect now.

Here is what a working in tact 'nub' looks like, It's not cracked :(Click for Larger Pic)


Rusted Springs and Pivot Points:



Piece of 1/8" ABS, screw and dab of epoxy for Fix:




Thanks for the post, Rob! ;D

[dlwiese]

Here is how I repaired the broken nub on the drivers side of my '98. Been using Rawn 'Plas-T-Pair for years on cars and planes. I will let it sit for about 24 hours before re-installing it in the door. Anybody tried to do a 3-D print of a new handle? When I get the time, maybe?