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2G Door Handles Help! [Merged 11-7] broke broken eBay replacement repair handle outside

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Thanks for the mention of my repair kit ($10 donated to DSMtuners). It is a permanent repair solution for anyone who has door handles painted to match the body color since there is no repainting involved.

I have always told people if you are smart enough to get the old handle out of the door you are certainly smart enough to use the repair kit. If you have limited access to tools or no area to work on your car then dropping in a black ebay handle is probably the best solution for you.

The non-OEM handles on ebay have authentically reproduced the same stress riser found in the design of the OEM handle hinges. Great job (sarcasm). This is the one time you wish they hadn't copied a part exactly the same. :)

Even if you don't use my repair kit, please check out these photos of how to remove the handle.
2G door handle removal tips
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There is no easy way to reach the 10mm bolt next to the key cylinder. It take dexterity and a little patience.

After pulling the cylinder retainer clip and getting the two 10mm bolts out I do have one trick to help remove the door latch push-down rod. That involves temporarily removing the Torx bolts to the door latch itself. Once those bolts are out you can raise and lower the latch within the door so the rod can be accesses from outside the car. The little plastic clip is not easy to access inside the door but it is much easier once the door handle has been pulled away from the door handle hole.
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Dave I just ordered your kit! Hopefully thisll fix that stupid freaking door handle.
 
Dave I just ordered your kit! Hopefully thisll fix that stupid freaking door handle.
Thanks. It's on the way.

Let me know if you have any questions when you do the repair. I always recommend the 24-hour cure JB Weld since a slow cure is easy to work with and stonger. Unfortunately that slows the overall repair job time since you have to wait for the cure. Do NOT use anything that cures in 5-6 minutes like JB Quik-Weld as those set up way too fast to get the steel inserts aligned.

I recently saw a new 1-hour cure gray colored marine epoxy at Home Depot (packaged in the small dual-tube syringes) so I'm trying that on a set of broken handles to see how it does before I recommend it. You don't want anything too brittle once it sets.

I'll wait another day or two before doing the 80# dead lift test. :D

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Wow dude, I received your email and cant beleive how fast you got that out after I ordered, thanks soooo much! You are definitely doing this community a favor.
 
Is that the Bondo putty? It's good stuff. I think Justice Brothers are also making a 2-part putty now.

As I've said before, your handle repair kit is possibly the single most valuable DSM product ever created.
 
Is that the Bondo putty? It's good stuff. I think Justice Brothers are also making a 2-part putty now.

As I've said before, your handle repair kit is possibly the single most valuable DSM product ever created.


Thanks again for all the +feedback here. Glad my idea is well received.

Here is the epoxy I am using now. Loctite brand 50-minute in a dual syringe. I really trust Loctite products so I was glad to see this in Home Depot. It has a 50-minute set time (meaning it gets unworkable after 50 minutes).
It still take 4-5 hours to be able to re-install the handle and probably an overnight cure should be used for for strength so it's not much faster than regular JBWeld but it is strong. I know some people have used faster cure rates and that is up to the installer. If you do, be sure you have the routine planned out before you mix the epoxy.

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Does anyone know if there are any good tutorials out there that will help me in doing this on a 1g DSM? I just received my door handles in the mail today and am eager to fix it. I am speaking of the exterior handle on the outside of the door itself.

Just wondering if you got OEM or ebay, and how it's working so far.

Also, does that "door handle fix kit" work with a 1g with slight modification?
 
does that "door handle fix kit" work with a 1g with slight modification?

My repair kit is only designed for 2G handles on Eclipse, Talon, Sebring, etc. I've never seen a 1G handle apart so I have no idea if the hinge designs are similar. I'm guessing my kit would not be useful to you.
 
This kit works great. Installed it on my already broken door handle and works perfect. Feels much stronger than before. The other side broke shortly after that so now I have to fix the other side.
 
If your still having issues getting the door to open, even though you just replaced the handle, try spraying WD-40 on the latch of the door and work it out with a screw driver or something.
I replaced my drivers side about 4 times in less than a year, and while the white clip was broken about half those time, the other half, I couldnt figure out why after I had just replaced it with a new handle, my door still wouldnt open. It felt like it was just not "catching" (sorry, terminology isnt as technical as you guys, but I'm trying, LOL).
Long story short, the lube fixed it right up. And to think I went through allllll those handles...LOL
If all else fails, try this...
 
Well both of my door handles broke around the same time so now i have to go through the trunk to get in the car.. very fustrating! I ordered new ones but the driver side still had trouble opening when i had the old one on. Any ideas why. I could open the passanger one with no issuses but i had to fight the driver side and then it just broke off.
stupid plastic crap.
 
Hey that's funny the only time ive done that is when two idiots park to close to me.
but if you look in the hole (if your's broke as bad as mine) there's a rod in plan sight just push straight down
 
my drivers door broke so i have to open my passenger door and reach accross. then walk around and pull it open. Its a PITA.
 
:mad: I'm about to burn this mf car! alright so here's my situation hope some one can help out... well my car has had a broken door handles for a while now.. i got to replace the passenger side with no problems... hated dealing with those damn orange clip.. shits...

And well to make a long story short, while replacing the driver door handle... that DAMN rod that opens the door broke! it seemed a bit brittle but know i can only unlock/lock the door, but i cant open it. i checked the part out on the Mitsubishiparts.com catalog, but i have to buy the whole assembly thing which is pushing $200's. any suggestions would be deeply appreciated. (sorry for the long post)
 
And well to make a long story short, while replacing the driver door handle... that DAMN rod that opens the door broke!

You mean the METAL pushrod that attaches with a plastic keeper to the front hinge joint of the handle? Many people should have one of those around from a junk door. I probably have a few.

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Hey guys. The little plastic door handle broke of when I lifted up on it trying to open my car door. I was wondering if I could just buy a new red handle and replace just the handle itself and not the whole door handle assembly, is this possible? If so awesome, if not would I have to replace the locking mechanism? looking for a driver side door handle off a 96 red TSI AWD. If anyone knows where I could find one that would help to. I've tried classifieds and DSM graveyard already. Thanks for the help!
 
I bought a few off ebay for $11 shipped. The only problem is the pivot point is really high, but I wrapped a thick piece of wire in the actuator arm and that lowers the engagement point well below the factory level. Works out nice.
 
It's kind of a rite of passage in the DSM world, door handles breaking off that is. My driver-side door handle broke off not too long ago. The ebay handles are a cheaper alternative to having to go to the dealer and pay $100 per handle OEM style. My advice, if you're in a fix and need handles ASAP, I would go the ebay route to cure your DSM access problem; all the while look for someone who is parting out the same color car and just buy the handles off of them. I was able to eventually find a pair of green handles (was a PITA to get that color, and I had to wait about 3 months) off of someone who had a wrecked 2g in the classifieds section. Red is a very common color, so you should be able to find a used, OEM door handle from someone parting their car out. Just remember to properly shim your handle when you install it so the door will open right every time! Good luck!
 
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