Exterior

Door Handle is Broken

> Went out to go to work this morning and couldn't open the drivers door on my
> '88. Worked fine yesterday. Symptoms: Don't notice any different feel to the
> handle and how it operates but it won't move the latch mechanism enough to
> open. It opens fine from the inside though. With the door open I can close
> the latch at see it open using the inside handle but not quite enough with
> the outside handle. It does move a little though. Any ideas? I don't want
> to dive into the door cavity if I don't have to.
> Tom Wiegand
> '88S4, silvermettalic, auto

Tom,
The inner part of the outer door handle mechanism is broken, this is very common (so common
most Porsche dealerships keep the drivers side in stock).

It is not expensive at around $38, but you will have to "dive into the door cavity" to replace it.


Let me know if you need any tips for replacement.

David Roberts
928 SPECIALISTS


Finally got around to tackling my door repair last night (handle not working from the outside).
Was able to remove the panel with no problem by following the procedure posted in 928OC
tips, thanks! However, when I got the panel off I was screwed. Could not figure out how to get
at the handle hinge as the window and locking mechanisms blocked my view and reach. Tried
to play Plastic Man and snake my arm in there but no luck. I didn't want to start unscrewing all
of the locking mechanism before I got some advice. Anyone........anyone........

Tom Wiegand
'88S4, silvermettalic, auto


Unbolt the window support from the riser. lower the window, then with the window in its
channel, tilt it forward. That should provide the space needed to access the handle
mechanism.

Merry motoring, Ed.



I just finished replacing the inner mechanism of the driver's side exterior door handle. The
symptom was that the handle was loose on one side, and it was close to breaking off entirely. I
had already previously replaced this interior part on both doors.

The entire operation took a total of three hours including breaks. It was tricky to do, so here is
how I got by the hard parts of it:

First remove the door panel as described elsewhere. Basically, there are about 6 bolts around
the side rest and at the front of the door inside the main air vent intake, plus a couple of
screws along the bottom of the door. The inside handle comes off by removing one screw and
sliding the plastic toward the rear and off. The round lock handle comes off by removing the

inner piece with a very small flat blade screw driver and removing a nut, then pull it off. The
round plastic guard piece itself unscrews and comes off. I left the wires and the panel attached
to the door, but supported off to the side.

Next carefully pull back the sheet plastic lining only enough to expose the openings in the
back half of the door. Make sure the window is completely closed.

Locate the anti-theft plate that goes next to the locking mechanism. Just loosen the nut and
bolt that hold its mounting bracket in place at the bottom front corner. Don't completely undo
them. It is designed to slide off once loosened. Now roll down the window all the way. Finish
removing the plate by unscrewing two screws: one located in a recess at the top edge of the
door and the other at the back side of the door at the top above the door latch. With the
window all the way down you can then maneuver the plate out.

Now once again close the window completely. Note you do not at any point have to loosen
the window glass nor remove it for this procedure.

Illuminate the inside of the door. Locate the lever attached to the door handle mechanism. Pop
it off with a medium sized flat blade screwdriver. At this point if you are a Pigmy brain surgeon
you can use an allen wrench to remove the two small bolts with washers that hold the exterior
door handle to the inner mechanism and then use a 10 mm wrench to remove the two nuts with
washers that hold the inner mechanism in place and replace it. There is some room for
adjustment so that the door handle does not rub on the door. Be sure to check this for smooth
operation before putting everything else back together.

I chose to remove the door locking mechanism to have better access. To remove it use an allen
wrench to remove two bolts that are slightly recessed along the top edge of the door and then
remove the two bolts holding the door latch also using an allen wrench. I was then able to
reach the lever from the door lock and pop it off of the door locking mechanism with a smaller
flat blade screwdriver. The entire door locking mechanism should then be lowered into the
door, and you will have a straight shot at the inner door handle mechanism. Replace as
described above. Be sure to adjust the door handle so that it doesn't rub against the door.

On reassembly first slide the door lock button back up through its hole. Then reattach the
lever from the door lock to the door locking mechanism. I was able to easily do this by first
removing the door lock, which is easy to do. Simply remove the rubber cover and with an allen
wrench remove the bolt and washer that hold the lock in place. With the lock held just outside
of its hole in the door, using a flat blade screwdriver reaching into the door lock's hole in the
door, I was able to press the lever back in place to its connector on the door locking
mechanism. At some point reattach the lock in the door with its bolt. I waited until I had the
following step done.

The last tricky step is to reattach the lever from the door locking mechanism to the connector
on the inner door handle mechanism. Do that from below by pressing it on with a medium
sized screwdriver.

Reassemble in the reverse sequence.

With the window all the way down, position the anti theft plate by sliding the lower bracket
onto the lower bolt and loosely secure it with the two screws, one along the top edge of the
door and the other just above the door latch. Then you should close the window and tighten
the nut and bolt.


Use adhesive spray or contact cement to resecure the sheet plastic and put the door panel
back on after checking to see that all the wires are still attached. Reattach the lock nob and
various small pieces.
--
Dan Shapiro
'82 928 5 speed "S package" Chiffon/Brown