IPD sale XeMODeX - Experts in Volvo Electronics
Did you know? 🤔
Logged in users can get email notification of topic replies Log in or register (free).
Amazon Link Buy anything with this and it helps MVS!

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

User avatar
KidsV70
Posts: 39
Joined: Fri Feb 15, 2019 5:34 pm
Year and Model: 2002 V70
Location: Virginia
Has thanked: 9 times
Been thanked: 2 times
United States of America
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
IMG_3910.JPG (105.76 KiB) Viewed 215 times
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
IMG_3914.JPG (105.19 KiB) Viewed 215 times
Above, the fix is in place, with cassette reinstalled.
IMG_3915.JPG
IMG_3915.JPG (103.74 KiB) Viewed 215 times
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

User avatar
oragex
Posts: 4942
Joined: Fri May 24, 2013 6:20 am
Year and Model: S60 2003
Location: Canada
Has thanked: 97 times
Been thanked: 286 times
Contact:
Canada
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

User avatar
KidsV70
Posts: 39
Joined: Fri Feb 15, 2019 5:34 pm
Year and Model: 2002 V70
Location: Virginia
Has thanked: 9 times
Been thanked: 2 times
United States of America
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
Posts: 246
Joined: Sat Sep 08, 2012 7:31 pm
Year and Model: 2006 2.5T S60
Location: Boston
Has thanked: 32 times
Been thanked: 23 times
United States of America
EngineeringBloke

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.

Geno9707
Posts: 25
Joined: Fri Oct 12, 2018 11:05 pm
Year and Model: 2004 s40
Location: Los Angeles
Has thanked: 0
Been thanked: 2 times
United States of America
Geno9707

Re: Another Solution for P2 Inside Door Handle breaking

Post by Geno9707 » Tue Nov 12, 2019 7:32 pm

Hello everyone I know how annoying this can get.. I had the same issue with my door handle.. to avoid headaches I had tried to repair the door handle prior but only to not fully work.. I did some research and you can replace the handle.. it was an easy job I purchase one on eBay for a great reasonable price.. here is the link.. you will be happy once you replace it.

EBay driver door handle Xc70 V70 S60
http://rover.ebay.com/rover/1/711-53200 ... olid=11111
These users thanked the author Geno9707 for the post:
- Pete -

User avatar
- Pete -
Posts: 704
Joined: Fri Dec 06, 2013 10:13 pm
Year and Model: 01, 04, 04, 04 V70's
Location: Minnesota/Wisconsin
Has thanked: 58 times
Been thanked: 100 times
United States of America
- Pete -

Re: Another Solution for P2 Inside Door Handle breaking

Post by - Pete - » Tue Nov 12, 2019 10:31 pm

EngineeringBloke wrote:
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.
You can unhook the cable at the other end. It's really pretty easy, not as easy as removing it from "this" end, but not any more aggravating once you see how it comes out.

The cable is BOWDEN 9485042, also searchable under Volvo part number 31253055, very inexpensive.
2001 V70XC 146k
2004 V70 AWD 141k
2004 V70R M66 144k
2004 XC70 287k
2006 XC70 155k Sold

Geno9707
Posts: 25
Joined: Fri Oct 12, 2018 11:05 pm
Year and Model: 2004 s40
Location: Los Angeles
Has thanked: 0
Been thanked: 2 times
United States of America
Geno9707

Re: Another Solution for P2 Inside Door Handle breaking

Post by Geno9707 » Sun Jul 19, 2020 10:55 am

Hello another solution is to buy it for a reasonable price and it comes with the whole kit to installed it hardware for the right price and it will avoid you from your repair failing again. Here is the link to purchase it. Hope this helps

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

Post Reply
  • Similar Topics
    Replies
    Views
    Last post