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Removing Your Rear Door Handles
 
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Pelican Technical Article:

Removing Your Rear Door Handles

Steve Vernon

Time:

2 hours2 hrs

Tab:

$75

Talent:

**

Tools:

T20 Torx, trim removal tool

Applicable Models:

Mercedes-Benz W203 (2001-07)

Parts Required:

Door handles

Hot Tip:

Get new gaskets

Performance Gain:

Doors that work

Complementary Modification:

Replace switches

This article will walk you through the steps of replacing your rear door handles. If you are going to be removing or replacing the backing plate on the door handle you will need to remove the door panel first. Please see our article on removing your front door panel. If you are just removing the handle you do not need to remove the door panel.

To begin removing the rear door handles you will need to loosen the single T20 Torx screw that screws into the end cover piece. You do this by first pulling back the weather strip on the inside of the door level with the handle revealing the access hole. There is a rubber body plug protecting the inner door that you will have to remove. Insert a long T20 Torx driver and unscrew the screw going into the end cover. You will have to do this by feel as you cannot see inside the door. Make sure you use a proper T20 driver and not a bit on the end of a socket. If you use a bit and it falls off inside the door you will be removing the door panel to retrieve it.

With the screw loosened, pull the cover out from the handle.

Pull the handle out and then towards the rear of the car to remove. When you are reinstalling the handle you will have to make sure the "L" shaped end goes behind the lever in the lock/latch assembly.

If you are removing the backing plate you will need to remove the door panel. Please see our article on removing your rear door panel. With that work complete.

Remove the door speaker and airbag. The speaker is held in place by three T20 Torx screws.

Make sure the window is all the way up, disconnected the battery from the car and for at least thirty minute before you begin work on the airbag. This will give enough time for the residual electricity to drain from the car.

Drill out the three rivets holding the airbag to the door frame. Turn the airbag away from you and disconnect the yellow connector.

Carefully peel the weather membrane away from the door. Leave the sticky stuff as you are going to be reinstalling the membrane.

There is a single screw holding the two piece foam insulator in the door located just bellow the door lock. Remove this screw with a T20 Torx.

You will need to reach inside the door and separate the foam block while in the door. Slide the two pieces apart and lower them separately through the door opening bellow.

To remove the backing plate, from the outside of the door, remove the two gaskets and then the two T20 Torx screws on the on the front and rear part of the handle.

You can now slip the backing plate down and out through the access panel on the inside of the door.

Installation is the reverse of removal.

To begin removing the rear door handles you will need to loosen the single T20 Torx screw that screws into the end cover piece.
Figure 1

To begin removing the rear door handles you will need to loosen the single T20 Torx screw that screws into the end cover piece. You do this by first pulling back the weather strip on the inside of the door (yellow arrows) level with the handle revealing the access hole. There is a rubber body plug (red arrow) protecting the inner door that you will have remove.

Insert a long T20 Torx driver into the access hole and unscrew the screw going into the end cover (red arrows).
Figure 2

Insert a long T20 Torx driver into the access hole and unscrew the screw going into the end cover (red arrows). You will have to do this by feel as you can not see inside the door. Make sure you use a proper T20 driver and not a bit on the end of a socket. If you use a bit and it falls off inside the door you will be removing the door panel to retrieve it.

With the screw loosened, pull the cover out from the handle (red arrow).
Figure 3

With the screw loosened, pull the cover out from the handle (red arrow).

This photo illustrates the T20 screw you that you cannot see while installed in the door (red arrow).
Figure 4

This photo illustrates the T20 screw you that you cannot see while installed in the door (red arrow).

Pull the handle (red arrows) out and then towards the rear of the car to remove.
Figure 5

Pull the handle (red arrows) out and then towards the rear of the car to remove. When you are reinstalling the handle you will have to make sure the "L" shaped (rear) end goes behind the lever in the lock/latch assembly.

Remove the two gaskets between the handle and door to gain access to the two T20 Torx screws holding the backing plate in place (red arrows).
Figure 6

Remove the two gaskets between the handle and door to gain access to the two T20 Torx screws holding the backing plate in place (red arrows).

Remove the door speaker (red arrow) and the airbag (yellow arrow).
Figure 7

Remove the door speaker (red arrow) and the airbag (yellow arrow). The speaker is held in place by three T20 Torx screws.

Drill out the rivets holding the air bag in place.
Figure 8

Drill out the rivets holding the air bag in place. Turn the airbag away from yourself and disconnect the yellow plug from it. Set the air bag aside face up.

Carefully peel back the weather and sound membrane from the inner door panel.
Figure 9

Carefully peel back the weather and sound membrane from the inner door panel. You are going to be reusing this so leave the sticky stuff on it (red arrow).

There is a two piece Styrofoam insert between the inner and outer door skins that is held in place by a single T20 Torx screw (red arrow).
Figure 10

There is a two piece Styrofoam insert between the inner and outer door skins that is held in place by a single T20 Torx screw (red arrow). Remove this screw.

This photo illustrates the Styrofoam insert.
Figure 11

This photo illustrates the Styrofoam insert. You can see how it slides together to create one part. This action must be done while the Styrofoam is in its position in the door. Slide the piece apart and remove from the door.

You can now slip the backing plate (red arrow) down and out through the access panel on the inside of the door.
Figure 12

You can now slip the backing plate (red arrow) down and out through the access panel on the inside of the door.

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