Saturday, September 22, 2007 - 02:20 pm, by: Robert Carlyon(Bob)
I noticed this morning that my door handle is catching at the top when you let it go and needs to be pushed back down to close fully.
I looked at the passenger side and there is a nice even gap all the way around the top, but on the drivers side its actually touching the top of the surround (hence where its catching).
Could I be leading up to the broken plastic clip that locks a metal rod into the handle as per the thread below? Any advice appreciated.
Saturday, September 22, 2007 - 02:59 pm, by: Michael O'Driscoll(Remickz)
Sounds like broken casting on the handle. You will have to pull the inside trims apart and have a look, but it sounds exactly like what my handle was doing, one side of the handle, the joints were broken where the springs are.
Saturday, September 22, 2007 - 03:06 pm, by: Robert Carlyon(Bob)
Thanks Michael, I'm going to remove the trim in the morning and have a look. I assume if it is a broken casting, I will need to replace the actual handle?
One thing I didn't mention was everything else is working fine (auto locking, window etc).
Saturday, September 22, 2007 - 04:57 pm, by: Kurt Porter(Silversoarer82)
hey Rob, if you can't open the door from the outside on the drivers side i have a spare door assy lock...not the external door handle (the thing inside the door! )
Sunday, September 23, 2007 - 11:04 am, by: Robert Carlyon(Bob)
**UPDATE** I pulled the trim off this morning and it would appear the problem is with the lock assembly. It looks like the door lock rod has been broken at some stage and has been welded up (the previous owner probably had a broken plastic clip and has wound the window down).
If you look in the pic below, the problem is where the yellow circle is, the rod is very sloppy compared to this and it is catching on the plate behind it (marked by yellow arrow). The bit that holds the rod also looks a bit bent.
I got in with the tip of my multigrips and after a bit of profanity I managed to bend it out a bit so its not catching for now.
I think to fix it properly I will have to replace the rod, which I assume its part of the locking assembly.
**Kurt**, if the rod is part of the assembly can you please PM me and let me know how much you want for it (my postcode is 5019).
Sunday, September 23, 2007 - 01:31 pm, by: Rod Iseppi(Rod)
rob - the paint shouldnt be chipping off the top of the handle unless there was another problem with the handle too? yeah the rod is part of the lock unit. they do wear out a bit an get movement causing them to click and catch - but usualy only after someones dodgied it up before.
Sunday, September 23, 2007 - 03:31 pm, by: Robert Carlyon(Bob)
Kurt and Rod, PMs replied.
Yes I think its been dodgied previously as someone has probably opened the window on the rod. So to fix it properly, I will replace the mechanism and the chipped handle.
Previous
I managed to bend it out a bit so its not catching for now. 
