crew
01-02-2013, 09:35 AM
Well, for no reason whatsoever, other than overuse, the cable release on my drivers inner door handle decided to snap. Apparently, this is a widespread issue on B6 and I will assume B7 as well. However, it's an easy (and cheap) fix.
Popped the door card off, and found that the hook was still attached to the handle itself, but the 2" at the end had broken from the rest of the cable at the very end of the sleeve.
The replacement cable assembly is approximately $40 from the dealer or elsewhere, so I decided to try something myself. I only have one picture, so bear with my description! You can see all pics and steps required of doorcard removal from my DIY for the window regulator:
http://www.audizine.com/forum/showthread.php/393612-B7-Window-Regulator-Tutorial
Needed: Wire strippers or pliers, wire coat hanger or equivalent gauge wire, power drill.
Time Req'd: 30 minutes to an hour
Skill Req'd: Basic hand tools
1. Remove doorcard, making sure to detach electronics harness and speaker leads. You'll also need to snap the white cable guide from the doorcard, which is likely where the end of the cable is severed.
2. Remove hook from inner handle, there will probably be about 2" of it total. Keep this.
3. Take wire strippers, pliers, a knife, etc.. whatever you choose to use to strip wires. CAREFULLY remove the last 2-3" of the black cable guide. You'll be left with an equal amount of the remaining release cable, right up to where it is severed from the hook assembly section. Keep the white cable guide at the end, as you will need it later.
4. Make short (approximately 1/2") 180-degree bends in the cable ends for the release cable. Depending on where your cable broke, you'll need an equivalent length of wire or hanger to make up for the bent sections. You'll be able to see this step most clearly in the photo below.
5. Depending on the gauge of wire or hanger used, you'll need to bore out the white cable guide we kept from earlier. Start small, and work up, this will keep it centered - I think I got up to 3/16", possibly 1/4". Only drill what you need to allow your new cable and link to pass clearly.
6. Pass the bored out white cable guide over the cable length that is still connected to the door, keeping the direction the same as previously.
7. Make 180-degree bends in both ends of your wire/hanger length, just enough to replace the length lost to bends in the two cable pieces. Attach wire/hanger length to the bend in the cable end, and attach the hook cable end to the remaining end. The total length should now be the same as before the cable snapped. Make sure your white cable guide is still there and will pass freely over everything without hitching. A thin wrap of electrical tape or shrink wrapping couldn't hurt, but I skipped this.
8. Reassemble. Note, you may have to tear down and do this several times to get it right. I did it with the window down, to make sure that the door opens - also, make sure the door electronics are fully reconnected and work (I made this mistake after full reassembly and had to do it again). Make sure you reattach the hook to the handle, and the white guide snaps back into place.
9. You should now have a stock-feel, sturdy inside handle, and you saved yourself $40. Spend it on beer.
http://i46.tinypic.com/2192tsw.jpg
Hope this helps someone!
Popped the door card off, and found that the hook was still attached to the handle itself, but the 2" at the end had broken from the rest of the cable at the very end of the sleeve.
The replacement cable assembly is approximately $40 from the dealer or elsewhere, so I decided to try something myself. I only have one picture, so bear with my description! You can see all pics and steps required of doorcard removal from my DIY for the window regulator:
http://www.audizine.com/forum/showthread.php/393612-B7-Window-Regulator-Tutorial
Needed: Wire strippers or pliers, wire coat hanger or equivalent gauge wire, power drill.
Time Req'd: 30 minutes to an hour
Skill Req'd: Basic hand tools
1. Remove doorcard, making sure to detach electronics harness and speaker leads. You'll also need to snap the white cable guide from the doorcard, which is likely where the end of the cable is severed.
2. Remove hook from inner handle, there will probably be about 2" of it total. Keep this.
3. Take wire strippers, pliers, a knife, etc.. whatever you choose to use to strip wires. CAREFULLY remove the last 2-3" of the black cable guide. You'll be left with an equal amount of the remaining release cable, right up to where it is severed from the hook assembly section. Keep the white cable guide at the end, as you will need it later.
4. Make short (approximately 1/2") 180-degree bends in the cable ends for the release cable. Depending on where your cable broke, you'll need an equivalent length of wire or hanger to make up for the bent sections. You'll be able to see this step most clearly in the photo below.
5. Depending on the gauge of wire or hanger used, you'll need to bore out the white cable guide we kept from earlier. Start small, and work up, this will keep it centered - I think I got up to 3/16", possibly 1/4". Only drill what you need to allow your new cable and link to pass clearly.
6. Pass the bored out white cable guide over the cable length that is still connected to the door, keeping the direction the same as previously.
7. Make 180-degree bends in both ends of your wire/hanger length, just enough to replace the length lost to bends in the two cable pieces. Attach wire/hanger length to the bend in the cable end, and attach the hook cable end to the remaining end. The total length should now be the same as before the cable snapped. Make sure your white cable guide is still there and will pass freely over everything without hitching. A thin wrap of electrical tape or shrink wrapping couldn't hurt, but I skipped this.
8. Reassemble. Note, you may have to tear down and do this several times to get it right. I did it with the window down, to make sure that the door opens - also, make sure the door electronics are fully reconnected and work (I made this mistake after full reassembly and had to do it again). Make sure you reattach the hook to the handle, and the white guide snaps back into place.
9. You should now have a stock-feel, sturdy inside handle, and you saved yourself $40. Spend it on beer.
http://i46.tinypic.com/2192tsw.jpg
Hope this helps someone!