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Door Handle Replacement
 
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Pelican Technical Article:

Door Handle Replacement

Nick Czerula

Time:

1 hour1 hr

Tab:

$200

Talent:

**

Tools:

Plastic prying tool, Door panel clip tool, Phillips screwdriver, 4mm allen wrench

Applicable Models:

BMW X5 (2000-06)

Parts Required:

Door panel, vapor barrier, vapor barrier seal, door panel clips

Hot Tip:

Have door panel trim clips on hand in case they break when removing and tape body to avoid scratches

Performance Gain:

Door opens normally

Complementary Modification:

Lubricate and clean door latch

The exterior door handle releases and unlocks the door latch via a bracket inside the door. The lock cylinder can wear out over time and become stiff and the handle malfunctions, usually at the connection to the inner bracket. It is quite easy to remove and replace, needing only a few tools and steps. If replacing the handle, you will have to have it painted to match your vehicle before installing. If you suspect the inner bracket has failed, you can check it by removing the door handle and manually actuating it.

In this tech article, I will go over how to replace the lock cylinder, outer door handle and outer door handle carrier on the driver side door. To replace other door handles you can use this procedure, the main difference being the lack of a lock cylinder.

Remove the door panel and door vapor barrier. When peeling the vapor barrier off, be careful not to tear it. If you do, replace it. See our tech article on door panel removing.

Using a plastic prying tool, gently lever out the rubber plug (green arrow) and then remove the oval ring the plug sits in.
Figure 1

Using a plastic prying tool, gently lever out the rubber plug (green arrow) and then remove the oval ring the plug sits in.

Next, you have to remove the lock cylinder fastener.
Figure 2

Next, you have to remove the lock cylinder fastener. Use a 4mm Allen wrench (green arrow).

Then slide the lock cylinder out of the door.
Figure 3

Then slide the lock cylinder out of the door. If the lock cylinder doesn't want to come out easily, you can gently lever it out using a plastic prying tool.

Pull the door handle out.
Figure 4

Pull the door handle out. Insert a tool in the lock cylinder access hole, jamming the handle open (yellow arrow). I used my plastic prying tool. Then remove the handle-mounting nut (green arrow). Pull the handle downward. If it won't release easily lightly tap the handle downward with a small plastic tipped mallet. Be careful not to mar the painted surface if reinstalling the same handle.

With the handle still jammed open rotate the handle 45°.
Figure 5

With the handle still jammed open rotate the handle 45°. Use a plastic prying tool to assist in pulling the handle off the front anchor. To remove the door handle carrier go inside the door and disconnect the Bowden cable from the door latch. Back outside the door remove the Phillips screw exposed when the outer handle was removed. The carrier will now be removable from inside the door. Reverse the steps to install the carrier. Install the door handle into the door in the reverse order of removing. Slide the lock cylinder into the door and tighten the fastener. Inspect the door handle seals and replace if needed. Install the vapor seal ensuring that it is water leak free, and then reinstall the door panel







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Page last updated: Mon 10/23/2017 03:14:03 AM