Repairing a broken gtv door handle - DIY

[jazig.k]

Another simple job to DIY knocked over. So first things first, anyone have a pair of cheap, similarly broken black door handles they want to sell me? I'm not a fan of the blue blue handles...

My drivers door handle was lifting out when you tried to open the door. It required 2 hands to open it, one for pushing the handle back in and the other to pull the lever.

I remember it being a common problem and winced at the price some of the ebay handles seem to be asking, so I was determined to fix it one way or another. After all, it was a scrap handle that wouldn't pass roadworthy as-is.

Image one, two and three... The handle removed. As you see, the threaded inserts have broken out. I'll blame this on over tightening when someone grabbed their 10mm 1/2 drive and "nipped" them up... the plastic was squished under the thread post and back bracket and was a mission to get the nut undone. But image 3 shows that the plastic is old and fatigued anyway in the one remaining post, and a good pull on the handle, maybe a bit too much, will break the handles too I suspect.

[jazig.k]

Image 1 - Take your 4mm drill, a little elec tape and prepare to decline your invite from next years pebble beach!

Image 2 and 3 - drill 2 new holes and tap them M5.

Image 4 -  refit, with 1 M5 washer and one M6 washer to make up for the hole size of the bracket. I figured I'd go M5 so if the threads pull out, I'll tap them M6 and loctite a stud in, but it seems fine. Don't use your 1/2" and breaker bar. These just need to be nipped a fraction more than finger tight.

Easy. And a whole lot cheaper than new/used door handles.

[jazig.k]

Oh, I should mention that keep the drill depth limited. 15mm seemed fair because it had a good bit of thread to engage but those plastic posts I drilled into are solid. if you feel it go through, likely you now have holes on the outer of the handle too which you need to plug up and dress.

[aflp]

nice job 

i have a few door handles for sale of various condition if you after some spare parts