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DIY 2005 XC90 INNER Door Handle Fix (Can't open from inside)

A mid-size luxury crossover SUV, the Volvo XC90 made its debut in 2002 at the Detroit Motor Show. Recognized for its safety, practicality, and comfort, the XC90 is a popular vehicle around the world. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America).
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cn90
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Volvo Repair Database DIY 2005 XC90 INNER Door Handle Fix (Can't open from inside)

Post by cn90 »

If you can't open the door from inside, check "Child Lock" thingy first. Happened to my RR door: cable came off INNER door handle.
Same issue in P80 (Volvo 850, S70 etc.).

Since this is an easy fix, I did all 4 doors with zipties and I have have tool and technique down.
It was only 10 min per subsequent door.

Chances are the plastic clip holding the door cable is cracked and this allows the cable to detach.
The good news is: this is easy fix, about 15 minutes max.


1. Watch this youtube video by "1AAuto dot com":




2. When prying the trim piece, pry gently to detach it so it moves a bit toward you. There are 3 tabs that click in. Don't break them.
Just gently pry it toward you, then up.

XC90-RR-Door-01.JPG
XC90-RR-Door-01.JPG (42.95 KiB) Viewed 4382 times


3. Then Torx 25 screws x2.

4. Pry around the door trim using upholstery tool wrapped with cloth.
* There are 9 plastic clips.
* Electrical connector(s): d/c it.

XC90-RR-Door-02.JPG


5. Now study the design where the cable is attached. Use your common sense.
* I drilled 5/32" holes for ziptie to wrap around the door cable.
* Just drill near the base of the side plastic partitions as shown, near the base, this way it is more solid.
Don't drill the hole near you, go for the base of the partition.

XC90-RR-Door-03.JPG


That is all, very very easy fix...
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

WilliamBoot
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Joined: Thu Mar 29, 2018 1:56 am
Year and Model: XC90 2006
Location: Prague

Post by WilliamBoot »

I couldn't quite make sense of your photos - wasn't sure what you were drilling, but took your advice to figure it out. When I'd finished, I looked again at your photos and they made perfect sense. Thanks! Obviously I'm not a visual person. :-)

Geno9707
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Year and Model: 2004 s40
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Post by Geno9707 »

Hello I had the same issue.. easy repair.. I got a well pre owned genuine Volvo door handle on eBay here is the link..
https://rover.ebay.com/rover/0/0/0?mpre ... 2446861108

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Roger_850T
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Post by Roger_850T »

I had a similar issue where the cable failed on my drivers door. I replaced the lock mechanism, too, but in retrospect it would have been fine to just replace the cable.

Nice photos!
'05 XC90 V8 140k
'95 854T 310k
'02 V70 159k
'03 S80 111k (crashed)
'93 945T 217k (gone to be parted out)
'87 245 300k+ sold, still going
'84 264 Diesel, RIP at 160k
'78 242 manual everything.
'73 P1800ES, fun until the rust set in...

zoli_m13
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Post by zoli_m13 »

Hi cn90,

Thx for the great idea - it works well in my 2001 S60.
viewtopic.php?f=9&t=69305&p=488870#p488870

Cheers!
2001 VOLVO S60 2.0T A/T 245K+ miles
https://goo.gl/photos/jS1z777LDqJSQqPDA

Geno9707
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Year and Model: 2004 s40
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Post by Geno9707 »

[quote=Geno9707 post_id=485073 time=1539407253 user_id=99218]
Hello I had the same issue.. easy repair.. I got a well pre owned genuine Volvo door handle on eBay here is the link..

https://rover.ebay.com/rover/0/0/0?mpre ... 2640607949

Geno9707
Posts: 28
Joined: Fri Oct 12, 2018 11:05 pm
Year and Model: 2004 s40
Location: Los Angeles
Been thanked: 3 times

Post by Geno9707 »

Hello update I was able to find the part to replace the inside door handle in the XC90 2003-2012 interior door handle here is the link..

http://rover.ebay.com/rover/1/711-53200 ... olid=11111

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