IPD sale Volvo Parts

S60 - Door Handle- Really? Replace the whole panel? Topic is solved

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive "P2" cars.
2001 - 2007 V70
2004 - 2007 V70 R
2001 - 2007 XC-70
2001 - 2009 S60
2003 - 2007 S60 R
vtl
Posts: 1319
Joined: Thu Aug 16, 2012 1:35 pm
Year and Model: 2005 XC70
Location: Boston
Has thanked: 3 times
Been thanked: 8 times
United States of America

Re: S60 - Door Handle- Really? Replace the whole panel?

Post by vtl » Mon May 18, 2015 5:37 pm

Too invasive. Really, duct tape and a two drops of super glue is all you need :)
2002 V70 (sold)
2005 XC70 (Telos Road took it. Did a chassis swap...)
2016 XC60

draser
Posts: 789
Joined: Thu Aug 18, 2011 10:49 am
Year and Model: 2005 S60 2.5T
Location: Detroit MI
Been thanked: 1 time

Re: S60 - Door Handle- Really? Replace the whole panel?

Post by draser » Wed May 20, 2015 10:40 am

If you can't fix it with duct tape it can't be fixed. Sorry, I had to throw that out there..
2005 Volvo S60 2.5T, Zimmerman/Akebono brakes
2012 Honda Accord, EBC slotted rotors

vtl
Posts: 1319
Joined: Thu Aug 16, 2012 1:35 pm
Year and Model: 2005 XC70
Location: Boston
Has thanked: 3 times
Been thanked: 8 times
United States of America

Re: S60 - Door Handle- Really? Replace the whole panel?

Post by vtl » Wed May 20, 2015 11:30 am

I did that, it works. Had exactly same situation like in last chrism's picture.
2002 V70 (sold)
2005 XC70 (Telos Road took it. Did a chassis swap...)
2016 XC60

NoSnowHere
Posts: 1
Joined: Sat Jan 16, 2016 1:32 pm
Year and Model: 2002
Location: Florida, USA

Re: S60 - Door Handle- Really? Replace the whole panel?

Post by NoSnowHere » Sun Jan 17, 2016 3:59 pm

I just fixed this door handle issue on my 2002 V70XC (aka XC70 Cross Country.)

I purchased a remanufactured handle a assembly via eBay (about $40-50 USD January 2016 -- included shipping.)

Tips:

First, BE CAREFUL when disassembling everything. These cars are getting to the age where ALL of the plastic parts are becoming brittle. Personally, the plastic "base" for the bottom bolt of the door-pull is a long, then, plastic part. When I attempted to remove the screw, it literally ripped/snapped the plastic (even with the tip of the torq screw.) There's really no way to avoid these types of collateral damage. Just try to minimize it.

Second, if you do an Internet search for the V70 door trim, you can probably find the Volvo-sponsored diagrams that explain how to remove/replace ALL of this stuff! They even talk about the metal retaining clips that I will discuss below.

Once the door panel is completely removed from the car, I took in into the house (better lighting, and protection from scratches. e.g. I set it face-down on my sofa to perform the repairs.)

Removing the black inner door latch assembly from the car is a bit challenging. BEFORE you remove this black assembly, you will either:
1.) Want to already have new circular metal "keepers" to use for reassembly; or
2.) My new door handle assembly included short pan-head SCREWS (instead of those stupid metal clips.)
Whichever way you go, make sure you have them ready BEFORE you remove the black part from the door. Else, you will be doorless for a while...

To remove the metal clips, the Volvo dealer's instructions say that you are supposed to pry-up on one side of the metal clip, then CUT them off with a pair of diagonal snips. Personally, I just used a flat-head screwdriver to pry them off. For the ones that are open/easy to access, use a sharp, but broad-headed flat-head screwdriver. The fat width of the head will provide enough leverage to twist it, and pry it up the full length of the plastic shaft. The recessed metal clips are a bit more challenging. For these, I used a sharp, but NARROW flat-head screwdriver, with a long shaft -- so you can reach down into those little holes, and dig the tip of the screwdriver behind the edge of the metal tabs. Then, use the length of the screwdriver as leverage to pry the metal tab up/out of the hole. BOTH of these metal tabs broke during this process, which made it easier to then grasp them with a pair of needle-nosed pliers, and pull them out the rest of the way.

The black handle assembly seemed to be spot-clued (maybe via just a hut glue gun) to the door? It wasn't SERIOUSLY/permanently glued to the door. I didn't have to use tools to pry the black assembly away. I just rocked it gently with my hands until it slowly broke free along the edge -- working my way all the way from one side, to the other.

Note: The new black assembly needed some minor "mods."
First, where the tweeter mounts, there was a little shiny/metal part to the tweeter (resistor or something?) In my model year, the old door handle base was notched to accommodate for this part. So, I just used a Dremmel tool to grind-down this plastic a bit on this new part, to make a similar notch. (easy.)

Second, the tweeter has a small alignment pin/nipple close to where the cables connect to it. On the part I received, the hole in the black plastic base/assembly wasn't properly aligned. Note: I don't think this step (and the pin/nipple) is really necessary, because the tweeter is held into proper position via clips around the whole thing. So, you could probably just cut-off that little nipple? But, I wanted to keep things looking as factory/original as possible, so I used a small drill bit to wobble-out the hole in the new plastic assembly, so it would accommodate the nipple/tip.

If you are going to use the short-screws that came with the new part, then you need to nip-off most of the plastic alignment shafts that the metal clips were attached to. You want these to become flat/flush with the new part. Just dry-fit it, and make some sort of mark/scratch on a few of them, so you get an idea of how much you need to remove. Then, pull the latch assembly back off of these alignment shafts, so you can nip them off with the tool of your choice. (I just used a sharp/decent pair of diagonal snips.) But, you could probably use some sort or razor blade, or maybe even the Dremmel tool, too.

Then, simply reassemble (using the screws, instead of the metal clips.) You want a TIGHT/SECURE fit. If the black part still wobbles when you reassemble it, then you probably didn't cut enough length off of the plastic alignment shafts. Note: These are the mounting shafts/backs to the door trim. So, if your trim is damaged, this is the IDEAL time to replace it, too! :-)

Everything goes back fairly normal/usual thereafter.

Hope this helps. The Chinese parts aren't perfect. But, they are good enough!

Peace.

chrism
Posts: 897
Joined: Wed Jan 28, 2009 9:38 am
Year and Model: S80 / 2005
Location: Atlanta, GA
Been thanked: 14 times

Re: S60 - Door Handle- Really? Replace the whole panel?

Post by chrism » Mon Jan 18, 2016 2:32 pm

I was at the P-n-P this past weekend for "half price weekend". I toyed with the idea of taking home a couple extra door panels just for this reason. I didn't do it as I can hardly navigate through my garage as it is. I'll probably be sorry I didn't grab them.

Geno9707
Posts: 3
Joined: Fri Oct 12, 2018 11:05 pm
Year and Model: 2004 s40
Location: Los Angeles
United States of America

Re: S60 - Door Handle- Really? Replace the whole panel?

Post by Geno9707 » Wed Oct 17, 2018 5:42 pm

Hello I had the same problem with my v70 same set up as a s60.. I was able to order a handle at eBay.. here is the link.. https://rover.ebay.com/rover/0/0/0?mpre ... 2461838491

Better than buying a whole panel got the whole job done in 30 minutes..

cn90
Posts: 6183
Joined: Wed Mar 31, 2010 9:54 am
Year and Model: 2004 V70 2.5T
Location: Omaha NE
Been thanked: 49 times
United States of America

Re: S60 - Door Handle- Really? Replace the whole panel?

Post by cn90 » Thu Oct 18, 2018 8:35 am

Not sure if the S60 setup is the same like my 2005 XC90, but the fix in the XC90 is drilling the holes + single zip tie:

viewtopic.php?t=72385
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

bas85
Posts: 1
Joined: Sat Jan 12, 2019 1:03 pm
Year and Model: s60 2005
Location: amsterdam
Netherlands

Re: S60 - Door Handle- Really? Replace the whole panel?

Post by bas85 » Sat Jan 12, 2019 1:20 pm

Ive also did the macgyver fix :)

if it looks stupid and it works its not stupid haha
Attachments
20181222_093909673_iOS.jpg
20181222_100604408_iOS.jpg

User avatar
abscate
MVS Moderator
Posts: 16199
Joined: Sun Feb 17, 2013 5:54 pm
Year and Model: 1999 V70T5, 2005 V70
Location: NYC
Has thanked: 147 times
Been thanked: 440 times
Trinidad & Tobago

Re: S60 - Door Handle- Really? Replace the whole panel?

Post by abscate » Sun Jan 13, 2019 4:56 am

cn90 wrote:
Thu Oct 18, 2018 8:35 am
Not sure if the S60 setup is the same like my 2005 XC90, but the fix in the XC90 is drilling the holes + single zip tie:

https://www.matthewsvolvosite.com/forum ... hp?t=72385
Drilling the stop crack hole is important in plastic! Find the end of the crack and relief the stress by drilling it out

A bread clip would fit perfectly as agussett plate to bridge the repair with SuperGlue (Tm?). Bread clips have been obsoletedfrom ACrepairs by zip ties of course.
1 SWMBO for 30 years
2 Volvos
3 VWs
4 Careers
5 cats/dogs/gears
6 Perfect Ladies in waiting
7 Drivers
8 Boats- with a big pointy metal thing on top

1999 V70 T5M 56 2005 V70 NA M56 VWs BMW

Post Reply

Who is online

Users browsing this forum: Brentscrazyptwo, dhollow2, EngineeringBloke, Shanestrait, XC70Rider and 60 guests