by Elliot Rees, from “Let’s Talk Alfa”, April 1998 AROC of North Texas
Are your Spider’s clamshell-type outer door handles scratched or pitted with corrosion? Are the locks sticking? Perhaps it’s time to service or replace them with new or better looking ones!
Skill: Novice mechanic with a little curiosity and patience. Time: One to three hours to complete each side.
• 7 millimeter socket or wrench • 8 millimeter socket or wrench • Large head Phillips screwdriver • Small flat blade screwdriver
• Small nail file or flat knife blade • Lithium grease
Tip 1. Work on one door at a time, starting with the driver (left) side.
Tip 2: Access to the outer door handle bolts is via the inside of the door.
Start the project by removing the following:
1 .The inner door handle is held by one Phillips screw that is concealed behind black plastic insert. A flat blade or screwdriver will lift the plastic insert out of the inner door panel.
2. The arm rest is held by 3 Phillips screws concealed by plastic chrome strip and rectangular shaped insert. Again, screwdriver will lift and remove the inserts.
3. Upper and lower door panels are secured to the door by Phillips screws and ‘poppers.’
4. Hopefully, a plastic liner is draped inside the door to pro- tect the door panels from moisture running down the win- dows. If missing, the door panels will warp. Gently raise the plastic ‘skirt’ upwards to expose window regulator and wires.
5. Raise the side windows to the fully closed position.
6. Driver’s door first, undo and remove four 8 mm nuts (A, B, C, D in Figure 2) on bracket one and two and the door lock.
7. Push the rearmost (left) side of the door handle out (away from you). Gently wiggle handle to free it from door.
To remove the lock from the door handle:
1. Place door lock face down on a cloth.
2. Undo 7mm nut, (E, Fig. 2); remove nut, washers and ‘arm.’
To remove the lock from the door handle (continued):
3. Note position of spacer (Fig. 3) and spring (Fig 4).
4. Hold door handle in your hand and gently push the lock tumbler (Fig. 5) outwards (toward the outside of the handle).
5. Be careful the ‘keys’ (Fig. 6) do not fall or ‘jump‘ out of the tumbler. (Each key has a small spring [Fig. 7] under one ‘shoulder‘ of the key).
6. On a pad of paper write, 1, 2, 3, 4, 5, and lay each key down in the same direction or position as it is removed.
7. After cleaning, grease the tumbler, springs, and keys with lithium grease and relocate springs (Fig. 7) and keys (Fig. 6) into the tumbler in the order and position as when removed.
8. Reinsert the tumbler into the door handle (using a thin knife blade or flexible metal nail file to compress the springs and keys into the tumbler housing). Note: From my experience, I recom- mend seeking the approval of your loved one before liberally applying grease onto her nail file!
9. Refit retainer tension spring (Fig. 4)
10. Refit spacer (Fig. 3), place the downward tab outside of the retainer tension spring Fig. 4.
11. Replace arm and washers, and tighten 7 mm bolt, (E in Fig, 2).
12. Reinstall door handle, from the inside of the door, secure brackets 1 and 2 (Fig. 2). Secure the door lock arm and tighten nuts A, B, C, D, E, in Fig. 2
13. Replace the vinyl sheet to protect the panels from rain water. 14. Install door panels, arm rest, inner door handle, and the job is complete!