Door Handle Issues

[FunkyGBrown]

Hi all,

Finally got around to replacing the drivers side Bowden cable after a few months of using the washer trick. This worked incredibly well until the washer decided to ping out of place, so figured I should replace the whole thing.

The cable has now been replaced, and testing the latch internally suggests all is working as expected. I'm now reassembling but cannot get the door handle to sit flush with the assembly.

After some fiddling around, the only way I can get it to fit is to raise the handle as it's inserted, but then it stays in the raised position.

Using a bit of force to push it in raises the door handle, which then doesn't return back down.

The handle doesn't open the locking mechanism at all, which suggests it's not making proper contact with the gears on the carrier?

The teeth look worn, but the handle worked fine up until I replaced the cable so unless it's broken during disassembly I wouldn't have thought that would cause it to not fit back in?

Attached some pictures of the gears and the raised position it sits in.

Any thoughts? I'm at a loss and it's too hot to persevere.

 

[bigwinn]

Looking at the lower tooth it looks very worn

But that doesn’t usually manifest in fitment issues it would be more an issue of operation

 

[FunkyGBrown]

Ok solved the seating issue! The Bowden cable at the handle end was fixed in place, so broke it free so the cable was free moving and it now slots into place perfectly. The gears must have been slightly out.

However, the handle still doesn't work. My guess is the Bowdon cable wasn't the issue in the first place and it's actually the gears on the handle not being able to pull the cable high enough?

 

[bigwinn]

I agree