General That damn door handle hinge!

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General That damn door handle hinge!

The part fails because of a fatigue fracture in the part of the hinge that's made from Zamac; this fatigue is made much worse if the hinge pin becomes stiff due to corrosion. The steel part of the new type has an anticorrosive coating, but as to whether this will stop the pin from sticking, only time will tell.

If the pin is lubricated with a corrosion-inhibiting grease when the new part is fitted, the repair will likely last the life of the car; if it is assembled dry (as most will be if the job is entusted to a garage), I'd say it's likely to fail again at some point.


I think I might spray some lithium grease in the handle where the hinge is in the hope that some will find its way through to the pin.
 
How apposite, mine broke this morning! problem is that it's not just the hinge at front of handle as the whole handle came off in my hand(n), clearly the rearmost component has also sheared off so will this mean a new handle? any thoughts? anyone had a complete handle assembly replaced at main dealer and what was the cost:eek:? mine is a late 2010 so well out of any warranty. Cheers JohnB
 
I think I might spray some lithium grease in the handle where the hinge is
Lithium? That definitely prevents the handle getting a bipolar disorder!
rolleyes.gif
 
How apposite, mine broke this morning! problem is that it's not just the hinge at front of handle as the whole handle came off in my hand(n), clearly the rearmost component has also sheared off so will this mean a new handle? any thoughts? anyone had a complete handle assembly replaced at main dealer and what was the cost:eek:? mine is a late 2010 so well out of any warranty. Cheers JohnB


Look on eBay, cheap as chips and almost as plentiful
 
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The driver's side broke yesterday afternoon. :mad:

Wish me luck,
Mick.

Good luck Mick ;).

This will eventually happen to all 500 owners, if they keep using the car for long enough. Lubricating the hinge before it fails is the only way to prolong its life. The easy way is to use a silicone spray can with a straw. The proper way is to dismantle the door to gain better access to the hinge; if you're going to do this, you may as well replace the hinge while you're in there as even one UK winter will have already taken its toll.

Make sure to grease the new one before fitting. With the right grease in the right place, the repair should last the life of the car. Put in dry, the replacement will likely last about as long as the original.
 
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I never got round to lubricating the hinges, because it looked too difficult to do properly ......... like you say, it would be best to dismantle first.

Yes, I will grease up the new one immediately before I fit it.

From what is says up-thread, the newer units are better than the old ones and the one I'm getting is the new type.

No real rush to do the job, as all is fine so the car isn't off the road. I just have to be careful and gentle with it.

Thanks,
Mick.
 
So long Daisy Duke was there was there. :)
Mmmmm, Catherine Bach... :p

Further to a post I made earlier in this thread, both original door handles are still intact on my 8.5 year-old Sport. Must squirt some more silicone lubricant into the mechanism this weekend... thanks for the reminder :)
 
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Mine lasted the 6 years I had the car, but I did squirt in some lubricant early in its life when I read about the issue on this forum.
Ironically, when I replaced it with a used 500X in February, the driver's doorhandle was loose in the fore-aft axis. Replaced under warranty. At least the routeing of the tailgate looms looks to have been better executed in the X!
 
Just been looking at the job and took a couple of photos for info.

It seems that the hinge pin has rusted solid and the handle end snapped off. The new hinge has its pin loose in the holes and drops out easily. I presume that when the new hinges is fitted that the pin will be held captive by the handle.

It'll be mid-week before I'll have the opportunity to replace the hinge.

Mick.
 

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Might be worth a squit on ours, do you think regular use of the handles increase their life as apposed to little use and corroding? Or pure luck
It's obvious that the driver's side of any car gets used more than the other side, so if a handle is going to fail, it's odds on that it'll be the driver's side.

It's difficult to see "inside" the passenger's side to see if it's corroding or whatever. I'm sure that with some spray oil/grease of some sort would find its way into the right place, but I can't see the hinge properly at all.

The broken one on the driver's side is easy to see, and I think that the hinge itself is rusted solid, so maybe - just maybe - the handle was working because the metal bracket by the hinge-pin was actually bending and then eventually snapped. I can't be sure of this until I get it off and look.

Therefore, it should be possible to tell if it's about to fail ......................... but I never noticed until it came away on Thursday afternoon. :eek:

As for lubrication, my new one will get well-lubed before I fit it, and as I'll be very familiar with the handle mechanism by the time I've fitted it, I'll have a feel for the way they work and possibly be able to make some assessment of the passenger side ........... and lube it too.

Never a dull moment with a 500. :)
Mick.
 
So do you reckon it can be successfully lubed from the outside without having to remove the door card?
From what I can see, no. Not successfully. You can't even see the hinge.

Maybe it can, but you'd be spreading lube all over the area, and it would make a mess dribbling down over your nice clean car.

This is as much as you can see with the handle pulled fully out with a good hinge.

Regards,
Mick.
 

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