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Broken Door Handle Articulator (hinge) Repair
MarcoVenturi
07-01-2013
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Just follow the
Old 29-02-2016   #30
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Re: Broken Door Handle Articulator (hinge) Repair

Quote Originally Posted by Buster Gonad View Post
I assume I now need a full replacement handle? Will this come with a new front hinge included, or will I still need the one I ordered earlier? I've checked the guides and can only see the one for replacing the front hinge.... Is there one for a full handle change that some kindly soul could post a link to?
Hi Buster.
Same thing happened to my wife's car. I fixed it a few weeks ago.
I bought a handle from eBay. Came with the front hinge too.
I couldn't find a guide for replacing the whole handle, but it was actually pretty easy, apart from the fiddly bit trying to get the rear end of the handle back into the door hole.
I don't have any photos but the guide here is still useful for getting the door card off etc. Once you've done that and got the vapour barrier opened (I managed to unstick mine without cutting or tearing it) it's pretty clear what you need to do.
Feel free to ask questions if you think I can help.
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Old 17-03-2016   #31
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MarcoVenturi... you're a genius. Following your simple instructions, I had this job done in an hour and fifteen (no rain, no soup and no BBC)! Many thanks!
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Old 20-03-2016   #32
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Re: Broken Door Handle Articulator (hinge) Repair

Hi Silicon,
Also about to embark on fixing both sides of the handle. I've got my part from eBay, but am wondering if it's possible to fit the new handle just at the point of the black plastic prong (which broke on the old one) that locks over the sprung hook. This would mean I could keep the rest of the old part with the key locking cylinder in. If the whole new part needs to used and then the key lock cylinder needs to swapped and this scares me, but I can't work out if there's a way to remove the handle from that hook.

It occurred to me that maybe you were you doing the passenger side with no lock?

I did find some instructions where they seemed to able remove the black plastic prong from the sprung hook, but it's not clear how.
Hope all this makes sense and you know which parts I'm referring to. I did try to post an image link but it won't let me post URLs as its my first post, (not until 5th).
Any advice on the lock issue welcome.
P.
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Old 20-03-2016   #33
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Re: Broken Door Handle Articulator (hinge) Repair

Bit the bullet and transfered the key locking cylinder from the old to the new handle, not sure what I was worried about, went fine and the new door handle is on successfully. Also happy to advice on the trickier parts of the process if anyone else is trying this.

Main problems I encountered were working out how to detach the rods when inside the door as it was tricky to get to, and prizing the back off the black plastic cover that goes over the locking cylinder. It now seems that stage might not have been nessesary, it's just a small clip that holds the cylinder in and this might be removable by prizing the black plastic just enough to pop it out, as I foolishly thought the lock came out the back but it slots in the front of the handle held only by the circular clip.
The rods were just a lot of fiddling and working out which way the plastic retainers popped off when you couldn't see to well into the door.
P.
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Old 17-09-2016   #34
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Re: Broken Door Handle Articulator (hinge) Repair

Quote Originally Posted by MarcoVenturi View Post
Attachment 111241

Just follow the pdf
Hi to all, I've just replaced my door handle hinge,(drivers side).

I did follow the excellent guide posted by, 'Marco Venturi' so thanks very much for that.

I did find it very difficult to use a spanner and pozidrive bit mainly due to my fingers being a bit fat so I decided to partially remove the door handle at the lock end which means removing a Torx head screw which is located at the inside end of the door near the handle. All I did was just grip the handle and move it around a bit ,(WD40 helped), and just pulled the handle out without removing all the mechanism . I had a look inside the door at the mechanism and smeared a bit of grease on anything that moved or could wear out. When I pulled the handle out I had much more room to work and used a Stubby Screwdriver to drive the retaining screw tight. The whole job took around an hour and I'm happy.

Just one more thing, the new hinge cost me 10:82 from a Fiat dealer and on removing it from the packaging I noticed the hinge pin was loose and it fell out so I presume there must be a reason for this? Maybe the looser fit will mean it lasts longer? But I'll leave up to you guys to reply to my theory?

I hope this helps and apologies if this has been mentioned elsewhere already

Cheers..
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Old 17-09-2016   #35
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Re: Broken Door Handle Articulator (hinge) Repair

Quote Originally Posted by SiliconS View Post
Could anybody who's had the handle break off completely please give me any tips for a repair? The PDF seems to cover a front-end hinge fix but I can't find any mention of the full-on fix.
Has anybody done the full door handle repair? I bought the articulator part and followed the excellent advice on the site but due to my own clumsiness broke the black lug at the opposite end of the handle whilst trying to tighten the front screw that so many have problems with. Unless I get some advice from the forum it looks as if my dealer is getting the job after all. Grrr!
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Old 17-09-2016   #36
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Re: Broken Door Handle Articulator (hinge) Repair

Quote Originally Posted by StuartK View Post
Has anybody done the full door handle repair? I bought the articulator part and followed the excellent advice on the site but due to my own clumsiness broke the black lug at the opposite end of the handle whilst trying to tighten the front screw that so many have problems with. Unless I get some advice from the forum it looks as if my dealer is getting the job after all. Grrr!
Nooooo! It's not a difficult job to replace the whole handle. I managed it (as described above) and don't remember it being especially tricky. The instructions in this thread covered about 80% of the overall complexity.
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Old 18-09-2016   #37
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Re: Broken Door Handle Articulator (hinge) Repair

Thanks for the encouragement but I think I'd be punching above my weight as I can't see how to undo the section of the handle that houses the door lock. Nor do I seem able to unhook the rods. It was really frustrating as I'd succeeded in replacing the articulator but was struggling to tighten it up when the other end snapped. I was so close to getting it done. I had bought a mini ratchet bit set from amazon - Laser 2562 Mini Ratchet Bit Set - 6pc - and had I waited until that arrived I know it would have done the job. I refitted the door panel and everything else today without any problems but don't want to order the part for 30 from ebay and then finish up doing more damage. Live and learn I guess.
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Old 08-10-2016   #38
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Re: Broken Door Handle Articulator (hinge) Repair

Hi guys! I have just gone through an exercise of replacing the hinge and I thought I'd chip in with my experience. First of all, thanks OP for the excellent guide! It sure did make my life easier and it prevented things being smashed in anger I got my hinge from an official Fiat dealer here in the Netherlands (Roermond) and it was around 10 EUR. Readily available on stock.
A few things I learned today:

1) When removing the chrome plastic cover around the handle, pry it gently from the side where the back of your vehicle is. Not top, not bottom, not front, but rear. Thats where the metal clip holding the cover in place is.

2) I figured that during this repair is much much much more easier to put the replacement hinge in if you remove the whole lock. Saves you a lot of hassle with a screw-bit and a spanner and the time you spend removing the lock is probably even less than trying to fit the screw in using mirrors and what not. The extra steps are to loosen one more bolt (from the side of the door) and remove one pulley/rod from the lock mechanism. To remove the rod from the mechanism, just put a flat screw driver under it and give it a gentle twist (see second picture). Mine came out quite easily. Once the pulley/rod and the screw are removed, slide the lock forward (towards the front of your vehicle, wiggle it a bit and gently pull out. It helps when you hold the handle "open" as the mechanism shrinks.
3) And now the best one! The white plastic thingy people have been asking about is actually a replacement one for the red plastic thingy that sits in the lock and holds the rod/pulley in place (see first picture). tadaaaaaa!! mine (red) didn't break when i pulled the rod out, so i threw the white one away I think Fiat kind of anticipates that the whole lock goes out during this repair. Which is a good thinking I guess

I hope this helps someone and again, thanks for the guide!




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Last edited by jackill; 08-10-2016 at 14:52.
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Old 29-01-2017   #39
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Re: Broken Door Handle Articulator (hinge) Repair

Quote Originally Posted by MarcoVenturi View Post
Attachment 111241

Just follow the pdf
Marco, could I possibly email you a photo of my door handle to ensure is is the right part to get please?
I have sent you a friend request via here.
Thanks Karen
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Old 31-01-2017   #40
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Re: Broken Door Handle Articulator (hinge) Repair

Hi Karen......if you post the photo on here Ill have a look at it for you.........it's a very small part, a hinge, that's usually required. In fact, it's pictured with the screw and "plastic captive nut" (like a wallplug for a screw) it comes with sat on my Fiat's black and white checked car seat in the Guide (or, if your pages are like mine, at the top of this page)
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Last edited by MarcoVenturi; 31-01-2017 at 10:22. Reason: Extra info included
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Old 24-06-2018   #41
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Re: Broken Door Handle Articulator (hinge) Repair

I had a go at this and all of the advice is good. Definitely use tape around a large area in case you drop something near the door.
Biggest issue I had was unscrewing and screwing up the screw. I had to use a flat blade screwdriver that fitted the posidrive screw perfectly to unscrew it.
I tried the screwdriver bit and spanner to do it up but could not get enough power to do it up as it was very tight.
So I once again used the flat blade. Success.
I looked at removing the handle or at least loosening it but I couldnt see any way of undoing it.
I found that once I had loosened a couple of the plastic parts that hold the door card on that I just gripped it tight and pulled it off. Took about 2 seconds.
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Old 19-03-2019   #42
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Re: Broken Door Handle Articulator (hinge) Repair

Thank-to @MarcoVenturi. A well as saving me money you saved me time as it can be done with your guidance in less than one hour.

I don't see a need to completely remove the door card by detaching wires and cables...just let it dangle.

I was able to use a stubby screwdriver on that awakward screw by loosening the Torx screw that others have mentioned.

I hope to regain some lost Brownie-points this evening.
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Old 01-11-2019   #43
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Re: Broken Door Handle Articulator (hinge) Repair

My handle broke at the front hinge and was replaced under warranty. I got to look at the old part. The metal surrounding the hinge pin was broken and the pin was completely seized. My 500 has 2 winters of use and salt may be the cause but the car gets light use of under 1000 km per month. The part was dry of lubricant, tolerances were tight and the pin is likely steel and surrounding hinge is pot metal which causes corrosion due to dissimilar metals and moisture/brine.
I believe we can extend the life of this part with a generous spray of first oil and then grease into the area. This would be best done before the part is installed but the hose on WD-40 and spray grease may have to do. I have done this to my passenger side and the new drive side handles.
Cheers
Ron
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Old 16-11-2019   #44
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Hey , great job uploading this. You were right the fiddly part, I struggle there quite a bit , in the end I chose to insert long screwdriver through the door .Also inserting the plastic washer through the new hinge was a bit of a nightmare .Overall made the trick , not a perfect job , but almost
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