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Replacing Mercedes Benz Door Stays
 
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Pelican Technical Article:

Replacing Mercedes Benz Door Stays

Steve Vernon

Time:

60 minutes60 mins

Tab:

$34

Talent:

**

Tools:

Philips screwdriver, trim removal tool, needle-nose pliers, small hammer

Applicable Models:

Mercedes-Benz W201 (1984-93)

Parts Required:

New door stays

Hot Tip:

Door panels are expensive, take your time

Performance Gain:

Doors that don't swing out into traffic

Complementary Modification:

Replace switches.

Over the life of your car, your front driver's side door will probably get opened and closed more than all the other doors, the trunk and hood combined. It can take a tremendous amount of use and sooner or later your door stays might start to weaken or break. If you need to replace your door stays, you will need to remove your inner door panel and the plastic vapor shield to gain access.

This article will show you how to remove your front door panel and replace your stays. It is not a difficult job, but the door panels can be very expensive so take your time and double check things. Also, if you are going to be working on your own car, it is a good idea to purchase a set of trim removal tools. They are a set of hard yet flexible plastic tools of different shapes and sizes that are used in removing trim pieces. They work a lot better than a flat-head screwdriver and there is nothing worse than ruining a "do-it-yourself" project by scratching up your car or damaging expensive interior pieces. Pelican Parts sells a full line of these tool sets for under $20.

Before you begin removing the door panel, you should park the car on level ground since nothing is more frustrating than working on the door while it is swinging open. It is also a good idea to get yourself a small box or container to keep all your parts organized.

First remove the plastic lock along the upper ledge. It just unscrews counter clockwise. The door panel is only held on by two (2) attached pieces of hardware. The first is the door lock trim piece. Remove this piece by unscrewing the Philips screw and pulling the trim piece straight back.

Second is the door pull handle. Begin by removing the set of control switches for the power seat. Using your trim removal tool, gently pry off each piece. The seat back switch rides on a small cylindrical post that has a circlip attached to it. Remove this clip using your needle-nose pliers. Once the clip is off you can use your trim tool to remove the cover plate for the seat switches. Unscrew the screws holding the switches to the door and pull them out from the door.

Next, using your trim removal tool, remove the trim piece at the top of the pull handle. Underneath, remove the 10mm nut. Now you can slide the housing for the interior door handle forward and out of the panel. Once it is forward, you can remove the actuator rod that connects the handle to the lock assembly behind it.

You have now removed everything that is bolted to the door panel. The Mercedes-Benz door panels are different from most other manufacturers in that they do not use compressible clips to hold the panel to the door. The Mercedes-Benz panels are held on to the door by hard plastic hooks that sit within pockets in the sheet metal of the inner door. Once you have all the hardware off the door, you simple need to lift the panel up and away from the door.

With the door panel removed, you will see what is referred to as a "vapor barrier" between the panel and the door. It is really just a piece of plastic held on by glue used to prevent any wind, weather or noise emitting into the vehicle. Some cars came with door speakers mounted between the door and panels so they will have to be removed before removing the plastic. Now, carefully, and I mean carefully, try and remove it in one piece so you can reuse it when putting the door back together. In the event the plastic is damaged, worry not, you can get some thin sheeting from your hardware store and recover the door with it.

Once the plastic is off you should open the door and remove the rubber protector over the hinge pin. Once this is pulled back, using your needle-nose pliers remove the small circlip at the bottom of the pin and gently tap the pin out. Be careful not to lose or misplace the washer between the upper part of the pull and the bracket that needs to go back.

Once the pin is removed, carefully open the door to give yourself access to the three 10mm bolts holding the stay in the door. Be careful here because the door is now free to fully swing open and can damage the body work if it swings too far.

Remove the three 10mm bolts and reach in through the lower opening in the door frame and remove the door stay unit. The unit can be removed with the window regulator in place.

Replacing is the opposite of removal. The wiring harness runs right along the inside of the door frame, so when reinstalling the unit, take care not to pinch this harness.

Shown here is the interior door panel.
Figure 1

Shown here is the interior door panel. You will need to remove the door lock pull (green arrow) lock trim piece (blue arrow), and the trim pieces by the door pull and seat switches (red arrows).

Begin by unscrewing the door lock pull.
Figure 2

Begin by unscrewing the door lock pull. It unscrews counter clockwise.

Next remove the lock trim piece by unscrewing the Philips screw and pulling the trim piece straight back.
Figure 3

Next remove the lock trim piece by unscrewing the Philips screw and pulling the trim piece straight back.

Using your trim tool remove the plastic pieces for the seat controls.
Figure 4

Using your trim tool remove the plastic pieces for the seat controls.

You will need to remove this small circlip (red arrow) before you can remove the trim face.
Figure 5

You will need to remove this small circlip (red arrow) before you can remove the trim face. Once the circlip is off, pull off the face plate.

Remove the door pull handle trim piece and unscrew the 10 mm nut behind it.
Figure 6

Remove the door pull handle trim piece and unscrew the 10 mm nut behind it. Once this is removed you can slide the complete handle piece forward and out of the door.

Once the handle unit has been pulled forward reach in and remove the actuator rod from the handle (red arrow).
Figure 7

Once the handle unit has been pulled forward reach in and remove the actuator rod from the handle (red arrow).

Here is the interior of the door panel.
Figure 8

Here is the interior of the door panel. You can see the 6 hooks that hold it to the door (green arrows). Insert upper right shows the plastic hooks.

With the door panel removed, you'll see the plastic moisture barrier on the door.
Figure 9

With the door panel removed, you'll see the plastic moisture barrier on the door. You'll want to carefully peel this off the inside of the door starting at the rear edge of the door. The idea is to peel it off in just a way so that it can be glued back onto the door later.

Shown here are the three 10mm bolts (red arrows) holding the stay unit to the inner door and the rubber pin and hinge protector.
Figure 10

Shown here are the three 10mm bolts (red arrows) holding the stay unit to the inner door and the rubber pin and hinge protector.

Slide the rubber protector onto the hinge and using your needle nose pliers remove the circlip on the bottom of the pin.
Figure 11

Slide the rubber protector onto the hinge and using your needle nose pliers remove the circlip on the bottom of the pin. Gently tap the pin up and out, taking care not to lose the washer (green arrow) that will need to go back when you are reinstalling the unit.

Open the door (careful not to let it fly open) and remove the three 10mm bolts holding the stay unit to the inner door.
Figure 12

Open the door (careful not to let it fly open) and remove the three 10mm bolts holding the stay unit to the inner door.

Reach in through the lower access hole and remove the unit.
Figure 13

Reach in through the lower access hole and remove the unit. When reinstalling make sure you do not pinch the wiring harness that runs inside the door panel right beside the door stay unit.

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Page last updated: Fri 12/2/2016 02:23:48 AM