Door Handle Replacement
Hi all.
Few days ago, I was in my beautiful '98 528i going somewhere on my daily
routine. When I got there, I pulled on my door handle to get out... The
handle ended up in my hand and $45K car is missing a door handle now...
Is my understanding that earlier E39 production cars are prone to this
problem. I do not know the production dates but it does not matter since the
fix is around $25 - $30 for the part. Check Pacific BMW or your local dealer.
The part # is 51 21 8 226 049.
The replacement part is obviously made of plastic. They do not replace just
the HANDLE but rather the whole handle housing: the black part on the side
of the door where the handle is rested. The new part looks absolutely
identical to the old part, so I thought I will be replacing them like
Christmas lights. But there is a slight difference and I will explain later
on what the difference is.
YOU DO NOT NEED TO TAKE APART YOUR DOOR ASSEMBLY.
The only thing that needs to be taken apart is the black handle housing. You
do not need to take the panel out.
1. You need to take the screw cap off (goes back only one way, so don't
worry). Use a flat head screwdriver.
2. unscrew the black screw (mine was black. there is only one screw there).
Use Phillips head screwdriver. It will make the housing loose.
3. You need to pull the housing back as far as it will let you go (not too
far, since it is still connected to the cable).
4. disconnect the cable. you will need to wiggle the whole thing and use set
of long nose pliers. The end of the cable is attached to a thick metal hook
and it is tricky to unhook that hook from the metal lever in the housing. Be
careful, do not break things. If the cable runs away from you into the
panel, do not worry, you can get it with your fingers.
5. Take the new assembly and hook the metal hook to the new assembly.
The trick part here is that the cable does not have much play (it is a BMW,
let me remind) and the hook does not want to go where it belongs. You need
to turn the housing the opposite way (180 degrees, it will be upside down,
shiny part still facing you) and using the pliers hook the hook from down
going up. Then you will need to turn the housing back 180 degrees. Do it
carefully so you do not catch with the housing the leather panels and don't
put scratches on the leather. It will look like if you put the hook from up
down.
Next step is very important.
6. The housing has a guiding groove that goes behind the panel. You need to
make sure that the metal cable goes into that groove and plastic sleeve from
the cable stays in the groove's wider opening as well. Otherwise, your
handle will be there but will not open any doors for you.
P.S.
Time indeed can show a lot...
On my first endeavour, I had the handle that broke off in the weak spot..
On my second "lucky" day, it was the metal pivoting head that broke off
where the lever attaches to the main cylindrical body of the pivot.
My explanation is that the driver's door handle takes the most abuse
in the car - every time a car is used or driven, the driver's door ( and the driver's
seat) are being used the most. The next one in abuse would be the front passenger
area, the next one is rear right side and the side that takes the least abuse
would be the rear left side.
