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Another Solution for P2 Inside Door Handle breaking

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive "P2" platform cars.

2001 - 2007 V70
2004 - 2007 V70 R
2001 - 2007 XC-70
2001 - 2009 S60
2003 - 2007 S60 R

KidsV70
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KidsV70

Another Solution for P2 Inside Door Handle breaking

Post by KidsV70 » Wed Aug 21, 2019 7:00 pm

Hey folks,

Got a solution to share. The V70's inside driver's door broke a while back. I scoured the web looking for ideas, found a few, and got started trying to make something work. Apparently mine had been "fixed" once before, as a piece of wood and a large binder clip fell out when we got the door panel off. Not sure what it was doing....

As I got looking at it, it was clear that the receptacle in the door panel was broken in the front and on one corner, letting the cassette with the cable pop out and causing the door handle to stick out. It worked, but it was clear it wouldn't last. I guess the binder clip prevented it from popping out entirely until we got the door panel off.

My solution was this: I had some leftover 1" square steel tube, and I cut a piece about the length of the cassette, and then cut one of the sides off the tube, leaving a 3-sided square. I carefully pulled the sides open further with vice grips so that it would fit snugly over the receptacle. The steel held the cassette in place, and magically it was fixed! I also used some "steel stik" epoxy putty to make for darn sure it wasn't going to pop off due to door slamming or other reason. See below for photos!
IMG_3910.JPG
The above shows how it it fits. I was test fitting it. That took a little bit as I didn't want to bend the tube too much apart.
IMG_3914.JPG
Above, the fix is in place, with cassette reinstalled.
IMG_3915.JPG
A photo showing the epoxy putty I applied. I also put a little scrap of sheet metal in place to help shore up where the plastic of the receptacle was broken. Not sure if it makes any difference, but it made me feel better. :-D

Hope this helps others with this common and expensive problem. It still blows my mind the Volvo fix is to replace the door panel...

Best,
Bert
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oragex
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oragex

Re: Another Solution for P2 Inside Door Handle breaking

Post by oragex » Thu Aug 22, 2019 4:35 am

Great fix. Good to keep in mind if one needs to undo again the door panel in the future, it's better to still be able to detach the handle cable. I also had such clip - but used a flexible metal that was just hooking about the cable pin, without glue.
Another option is to get a spare black piece assembly from the junkyard and swap it all together www.youtube.com/watch?v=Jd7JNhUrD1g



KidsV70
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KidsV70

Re: Another Solution for P2 Inside Door Handle breaking

Post by KidsV70 » Thu Aug 22, 2019 5:17 pm

Good point. It would be a lot easier to remove the door panel without the epoxy! :-D



EngineeringBloke
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Re: Another Solution for P2 Inside Door Handle breaking

Post by EngineeringBloke » Tue Aug 27, 2019 9:15 am

I have removed the inner door cover many times upgrading my door speakers and then replacing one when it failed. I can see that it might be possible to move the cover away leaving the cable attached but it might put pressure on the 'fix' and break it. The panel would be more likely to be damaged when put down to work on the other part of the door.

So I also vote for a removable fix.



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