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  1. #1
    Active Member Four Rings Ben@SpeedBarn's Avatar
    Join Date
    Feb 11 2004
    AZ Member #
    42
    My Garage
    03 A6 2.7t, 00 GTI, 76 GMC
    Location
    Pittsburgh, PA

    Clunky door handle

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    On our 03 A6 the driver's side door handle is pretty clunky. When opening from the inside or the outside it isn't smooth at all. Almost like it's catching on something when pulling the handle. Anyone else have this issue? Pictures of the mechanism, or even pictures of taking the door panel off?

    Thanks.

  2. #2
    Veteran Member Four Rings 02 A6 2.7T's Avatar
    Join Date
    Nov 19 2006
    AZ Member #
    13513
    My Garage
    Too much crap
    Location
    WA

    Re: Clunky door handle

    Door latches on these cars can be problematic. The most common problems seem to be the door contact switch (interior lights, buzzer, door ajar, etc.) and the latch sticking.
    This is a very detailed write-up on repairing the latch, with lots of great pics:
    http://www.audiworld.com/tech/elec96.shtml
    I am opting to replace the latch part number 4B1837015H, which I got for $130.76 from http://genuineaudiparts.com/
    2002 A6 2.7T - 6MT Crystal Blue APR Stage 1
    2002 S6 - 6 MT Black/black
    **SOLD ** 2002 allroad 2.7T 6MT

  3. #3
    Forum Moderator Four Rings Daft's Avatar
    Join Date
    Feb 17 2004
    AZ Member #
    620
    My Garage
    Stg 3 '04 A6 2.7T, Stg 2 '14 S4, 2016 SQ5, 2019 RS5 coupe
    Location
    Sterling, VA

    Re: Clunky door handle

    Quote Originally Posted by Ben@SpeedBarn View Post
    On our 03 A6 the driver's side door handle is pretty clunky. When opening from the inside or the outside it isn't smooth at all. Almost like it's catching on something when pulling the handle. Anyone else have this issue? Pictures of the mechanism, or even pictures of taking the door panel off?

    Thanks.

    This is exactly what my driver's door is doing too. I really have been meaning to get to the bottom of it lately. I have noticed that it happens on both handles (In & Out) but, there are times that it works normally.

    Just from a mechanical standpoint, if the latch wasn't tight and the handle were lifted, you probably would feel some resistance until the latch was moved enough to release the door. It definitely seems that the latch is the issue in this type of problem.

    The strike plate/bar that the door latches onto shows no signs of abnormal wear or marks that are too far towards the top/bottom.
    Brett - Moderator
    Issue?: email me.
    _____________________
    Stage 3 2004 A6 2.7T 6M

  4. #4
    Veteran Member Four Rings 02 A6 2.7T's Avatar
    Join Date
    Nov 19 2006
    AZ Member #
    13513
    My Garage
    Too much crap
    Location
    WA

    Re: Clunky door handle

    Quote Originally Posted by Daft View Post
    This is exactly what my driver's door is doing too. I really have been meaning to get to the bottom of it lately. I have noticed that it happens on both handles (In & Out) but, there are times that it works normally.

    Just from a mechanical standpoint, if the latch wasn't tight and the handle were lifted, you probably would feel some resistance until the latch was moved enough to release the door. It definitely seems that the latch is the issue in this type of problem.

    The strike plate/bar that the door latches onto shows no signs of abnormal wear or marks that are too far towards the top/bottom.
    I found that a liberal application of white lithium spray grease (in and around the striker pawl mechanism) will temporarily fix the sticky latch. Unfortunately, it hasn't done a thing for my broken/corroded door contact switch...I need to replace it before I leave the lights on and kill the battery .
    2002 A6 2.7T - 6MT Crystal Blue APR Stage 1
    2002 S6 - 6 MT Black/black
    **SOLD ** 2002 allroad 2.7T 6MT

  5. #5
    Established Member Two Rings 2000 A6 2.7t 6m's Avatar
    Join Date
    Jul 27 2007
    AZ Member #
    19856
    Location
    PA

    Re: Clunky door handle

    I have similar issues. I spray it occasionally with white lithium which helps, but doesn't fix it. If you find a solution for under $130, please post it.
    Click for Photo Album
    Upgrades:
    APR 93 ECU -=- H&R Coilovers -=- H-Sport Swaybars -=- VMR B7 RS4 Reps in Onyx Black -=- Upgraded Sound System

  6. #6
    Forum Moderator Four Rings Daft's Avatar
    Join Date
    Feb 17 2004
    AZ Member #
    620
    My Garage
    Stg 3 '04 A6 2.7T, Stg 2 '14 S4, 2016 SQ5, 2019 RS5 coupe
    Location
    Sterling, VA

    Re: Clunky door handle

    Quote Originally Posted by 2000 A6 2.7t 6m View Post
    If you find a solution for under $130, please post it.
    Does that mean that you were quoted $130 to replace your latch?
    Brett - Moderator
    Issue?: email me.
    _____________________
    Stage 3 2004 A6 2.7T 6M

  7. #7
    Active Member Four Rings Ben@SpeedBarn's Avatar
    Join Date
    Feb 11 2004
    AZ Member #
    42
    My Garage
    03 A6 2.7t, 00 GTI, 76 GMC
    Location
    Pittsburgh, PA

    Re: Clunky door handle

    I think the latch itself is 130.

  8. #8
    Veteran Member Four Rings 02 A6 2.7T's Avatar
    Join Date
    Nov 19 2006
    AZ Member #
    13513
    My Garage
    Too much crap
    Location
    WA

    Re: Clunky door handle

    Quote Originally Posted by Ben@SpeedBarn View Post
    I think the latch itself is 130.
    BINGO! See post#2 above... the AW tech article shows how to remove & install it.
    2002 A6 2.7T - 6MT Crystal Blue APR Stage 1
    2002 S6 - 6 MT Black/black
    **SOLD ** 2002 allroad 2.7T 6MT

  9. #9
    Active Member Four Rings Ben@SpeedBarn's Avatar
    Join Date
    Feb 11 2004
    AZ Member #
    42
    My Garage
    03 A6 2.7t, 00 GTI, 76 GMC
    Location
    Pittsburgh, PA

    Re: Clunky door handle

    The audiworld write up doesn't really describe removing the door panel. Do any of you have experience with that? I hate pulling on things when you don't know if there is another hidden screw you missed. I'm going to try looking at it this weekend.

  10. #10
    Forum Moderator Four Rings Daft's Avatar
    Join Date
    Feb 17 2004
    AZ Member #
    620
    My Garage
    Stg 3 '04 A6 2.7T, Stg 2 '14 S4, 2016 SQ5, 2019 RS5 coupe
    Location
    Sterling, VA

    Re: Clunky door handle

    Quote Originally Posted by Ben@SpeedBarn View Post
    I think the latch itself is 130.
    Ahhhh.

    I'll bet you that I can find it for waaaaaay less than that.

    I'll report my findings.
    Brett - Moderator
    Issue?: email me.
    _____________________
    Stage 3 2004 A6 2.7T 6M

  11. #11
    Established Member Two Rings 2000 A6 2.7t 6m's Avatar
    Join Date
    Jul 27 2007
    AZ Member #
    19856
    Location
    PA

    Re: Clunky door handle

    Door panel removal isn't hard. Two screws, one on each side near the top of the door. The window switch can be popped out with a screwdriver in the little hole under the door handle. Disconnect the wiring, then the whole panel slides up.
    Click for Photo Album
    Upgrades:
    APR 93 ECU -=- H&R Coilovers -=- H-Sport Swaybars -=- VMR B7 RS4 Reps in Onyx Black -=- Upgraded Sound System

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