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Passenger door fixes Posted by un4gvn1 [Email]  (#2498) [Profile/Gallery]
(more from un4gvn1) on Sun, 9 Jun 2019 15:11:03
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1994 9000 Aero, auto, etc. None of which really matter to this post, trying to get in the habit of including the relevant info...
Previous owner suggested not using the passenger window, as it would sometimes not go up correctly. The other issue was the passenger door was very difficult to open from the outside. If you yanked quickly enough you could get it to unlatch, but the wife couldn't make it work most of the time.
Last week I finally got the time to tear into the door to attempt to address these "livability" issues.
The window was stupid easy. The bolt at the top of the guide was loose, allowing the window to wedge in the track. It literally took longer to grab a 10mm socket & ratchet than it took to effect the repair!
The door latch, not so easy...
After getting the sound/water barrier out of the way, I was (barely) able to look up into the latchworks and see that there was a gap between the roller on the outside latch and the vertical bar it engages to trip the latch. I guess the gap at around 1/8"-3/16".
The easy fix would have been to simply bend the vertical bar towards the interior of the car, thus reducing the gap. However, as the roller assembly that bolts to the outer latch handle is cast white metal (aka - "pot metal") which is notoriously unforgiving & brittle I deemed the "easy" fix too dangerous to attempt.
With much colorful language and fumbling in a blind hole I was able to unbolt the roller arm from the outer door latch handle.
Keep in mind that for almost this entire job I could either see, or have a hand or two in the door, but almost never both at the same time.
Once the roller bracket was clear, and the linkage to the inner latch handle removed (also the lock link) I was (just) able to slip a short piece of stiff plastic tubing over the vertical bar to fill most of the gap. This process was made more interesting by the need to keep the latch at "half cock" in order to access the top of the bar.
Another 30 or 40 minutes of colorful language later and the door was back together!
Long story a little longer...
ONE FINGER! One finger is all it takes now to open the passenger door from the outside.
I'm putting this one in the "win" column!
_______________________________________ Originally Posted by pdcomm "Experience is what enables you to recognize a mistake when you make it again. "
, Sun, 9 Jun 2019 15:11:03 <-- Viewing This Message, Mon, 10 Jun 2019 12:54:38, Mon, 17 Jun 2019 15:08:51
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