LWM
07-30-2010, 01:30 PM
Materials:
Plastic epoxy from Loctite
Nylon spacer 3.8" x .171" x 1"
https://theultimatejeep.com/notfound.pnghttps://theultimatejeep.com/notfound.png
Once you have materials, time to take off the door panel. There are three screws to remove
https://theultimatejeep.com/notfound.png
Next remove the window switch pack. Gently pry it upwards, then disconnect the three pack wire connections
Then the rest of the panel comes off with standard push clips. You can pry them out with trim tool or pull with your fingers. Clip locations below in black arrows. You will also need to remove 3 more wired connections (red), and the door handle release (green) in order to get the panel off the car.
https://theultimatejeep.com/notfound.png
From there, you can see where the handle is broken off at the pivot pin. You want to take a large drill bit or dremel and grind out a nice little pocket for the nylor spacer to sit in.
https://theultimatejeep.com/notfound.png
Next take the nylon spacer, and drill out the center slightly larger so the pivot pin can slide in and out easily. I used a 13/64" drill bit. Then cut the spacer in half. Time for a trial fit. You may need to do some additional trimming of the spacer and the door panel to get a nice level fit, and one that will not impede with the door handle itself.
https://theultimatejeep.com/notfound.png
Once things line up well, go ahead and mix a little of the epoxy. Leave the handle and spring out, just use the pin and the spacers. Take care not to glue the pin to the spacers, or get any glue on the inside pin area where the handle rides.
https://theultimatejeep.com/notfound.png
Let this dry for 20-30 minutes, then remove the pin. Grind off any epoxy that is in the way of the handle, and the reassemble the pin, spring, and handle. Glob some more epoxy over everything to make sure you have a good bond Once again, make sure you dont glue the handle in place. (SEE EDIT ON BELOW POSTS, DONT ASSEMBLE SPRING LIKE THIS)
https://theultimatejeep.com/notfound.png
Let dry. Epoxy will turn dark yellow, and get very hard.
https://theultimatejeep.com/notfound.png
Handle from other side, before reinstalling
https://theultimatejeep.com/notfound.png
Put the door panel back on just the way you took it off. Dont forget the wire connections or hooking up the door release wire. Sucks to take everything back apart again when you forget.
Enjoy the cheap fix! This looks like it is going to work and hold for a long while!
Information found at the attached link (http://www.jeepcommander.com/forums/showthread.php?t=13095)
Plastic epoxy from Loctite
Nylon spacer 3.8" x .171" x 1"
https://theultimatejeep.com/notfound.pnghttps://theultimatejeep.com/notfound.png
Once you have materials, time to take off the door panel. There are three screws to remove
https://theultimatejeep.com/notfound.png
Next remove the window switch pack. Gently pry it upwards, then disconnect the three pack wire connections
Then the rest of the panel comes off with standard push clips. You can pry them out with trim tool or pull with your fingers. Clip locations below in black arrows. You will also need to remove 3 more wired connections (red), and the door handle release (green) in order to get the panel off the car.
https://theultimatejeep.com/notfound.png
From there, you can see where the handle is broken off at the pivot pin. You want to take a large drill bit or dremel and grind out a nice little pocket for the nylor spacer to sit in.
https://theultimatejeep.com/notfound.png
Next take the nylon spacer, and drill out the center slightly larger so the pivot pin can slide in and out easily. I used a 13/64" drill bit. Then cut the spacer in half. Time for a trial fit. You may need to do some additional trimming of the spacer and the door panel to get a nice level fit, and one that will not impede with the door handle itself.
https://theultimatejeep.com/notfound.png
Once things line up well, go ahead and mix a little of the epoxy. Leave the handle and spring out, just use the pin and the spacers. Take care not to glue the pin to the spacers, or get any glue on the inside pin area where the handle rides.
https://theultimatejeep.com/notfound.png
Let this dry for 20-30 minutes, then remove the pin. Grind off any epoxy that is in the way of the handle, and the reassemble the pin, spring, and handle. Glob some more epoxy over everything to make sure you have a good bond Once again, make sure you dont glue the handle in place. (SEE EDIT ON BELOW POSTS, DONT ASSEMBLE SPRING LIKE THIS)
https://theultimatejeep.com/notfound.png
Let dry. Epoxy will turn dark yellow, and get very hard.
https://theultimatejeep.com/notfound.png
Handle from other side, before reinstalling
https://theultimatejeep.com/notfound.png
Put the door panel back on just the way you took it off. Dont forget the wire connections or hooking up the door release wire. Sucks to take everything back apart again when you forget.
Enjoy the cheap fix! This looks like it is going to work and hold for a long while!
Information found at the attached link (http://www.jeepcommander.com/forums/showthread.php?t=13095)