Sunday, January 22, 2012 - 07:07 pm, by: Maureen Tyler(Min)
I have 1991 Coupe and the drivers outside door handle doesn't work. I have removed the trim and the "arm" has broken and also the clip. I assume I have to take the locking mechanism out to weld the arm but don't know how. Can anyone help? I need step by step instructions.
Ben Lipman Goo Roo SA Soarer TT manual, plus TT track car
Sunday, January 22, 2012 - 07:30 pm, by: Ben Lipman(Ben12a)
Is it the actual door latch mech or handle you need to remove?
Door handle: If you can see the inside of the door handle, you need to undo the two screws (might be easier to remove the key barrel (1 Screw) as this makes access to the second screw easier. It then lifts up and out from the outside. You will need to undo the plastic clips on the door arm and lock arm. As you discovered after 20 odd years they can become fragile.
Door latch: is held in by 3 torx fasteners that are undone from the outside of the door (surrounding the catch part you can see). I have found I also need to undo the window rail (window needs to be in the up position) closest to the catch to allow you to wiggle the door latch mechanism out of the door. This is done by using a large phillips head and undoing the recessed screw down the lower portion of the door at the catch end.
Maureen Tyler Newbie south australia coupe v8 limited edition
Sunday, January 22, 2012 - 07:38 pm, by: Maureen Tyler(Min)
Thanks. It is the door latch that I need to get out. When I take the 3 screws out will the whole mechanism come out? and is there another arm, with a red clip that I have to detach. Also what happens to the cables connecting the internal door handles.
Ben Lipman Goo Roo SA Soarer TT manual, plus TT track car
Monday, January 23, 2012 - 06:10 pm, by: Ben Lipman(Ben12a)
Yes the whole box and dice will come out. There are two arms, one to the handle, one to the key barrel.
The cables go to the interior door handle and lock switch. They come out by rotating out and sliding out via the recess (will become obvious).
As I said, the mechanism will be caught up behind the window rail. It will be like a chinese puzzle to get out, so I suggest removing the screw (and maybe the next one up if needed) that holds the window rail to the inner door so you can gently push it out of the way.
Ben Lipman Goo Roo SA Soarer TT manual, plus TT track car
Monday, January 23, 2012 - 06:13 pm, by: Ben Lipman(Ben12a)
Where are you? I have been working on doors for the last few weeks, so it would take me a couple of minutes to get it out, and I could Mig it for you here on the spot.
I'm out north in Playford.
Maureen Tyler Newbie south australia coupe v8 limited edition
Monday, January 23, 2012 - 07:08 pm, by: Maureen Tyler(Min)
I am down south at Port Willunga so probably too hard at the moment especially in this heat. I am quite happy to undo the window rail as you said and expect the cables to wriggle out as we go. The only thing stopping from getting started is, do I need to disconnect the arm to the key barrel first or can I leave it. I am guessing if it does need to be disconnected I will need to push the bottom of the red clip off and the arm slides out, similar to the handle arm. Will the clip break easily. Thanks so much for your help.
Ben Lipman Goo Roo SA Soarer TT manual, plus TT track car
Monday, January 23, 2012 - 09:19 pm, by: Ben Lipman(Ben12a)
I have broken 3 out of 4, so I would be nice and careful.
I need to get to sprint or somewhere and see if they sell them- they seem to be the same on every car I have ever worked on. I will need new ones when I fit up my fibreglass doors.
You might be able to get it out with the key barrel still connected via the arm.
Maureen Tyler Newbie south australia coupe v8 limited edition
Saturday, February 11, 2012 - 05:18 pm, by: Maureen Tyler(Min)
Have just finished replacing the door handle and it works. Yeh!! Had some fun with it along the way. As the arm was broken, we had it welded, but a combination of not a very good weld and me not being very careful saw me break it again. This time the guy made an new bit for the end of the arm and welded it on, a much stronger piece now. And on re-reading the instructions saw that you remove the cables from the mechanism which made it a whole lot easier. Simple really if you do it right. Thanks heaps. We are having a bit of fun getting a few things sorted out. Cheers
Ben Lipman Goo Roo SA Soarer TT manual, plus TT track car
Saturday, February 11, 2012 - 06:31 pm, by: Ben Lipman(Ben12a)
I discovered you can't buy those plastic clips from any old auto parts store. They are OEM only, apparently. Toyota want over $8 each. I bought a bag of them from the US for this price (although postage was $12, LOL.) Should arrive soon. I have a couple of doors that will need them.
Maureen Tyler Tinkerer south australia coupe v8 limited edition
Sunday, February 12, 2012 - 10:34 am, by: Maureen Tyler(Min)
Yeh, we found that out. Paid $10.40 from CMI Toyota. Have ordered some other parts, inner door handles and a few other bits and pieces, from overseas and very reasonable prices compared to CMI. Hope they arrive now. If we need another clip, I will keep you in mind and see if you have any spare. LOL. Cheers
Peter Nitschke Junk Filterer South Australia UZZ30 UZZ31
Sunday, February 12, 2012 - 07:01 pm, by: Peter Nitschke(Pen)
After fitting a new clip (second time), I also put a twisty around the bar to stop it dropping into the way of the window if the clip ever breaks again.
Maureen Tyler Tinkerer south australia coupe v8 limited edition