Door Handle Replacement-Good News

[TMKHUM]

All-

I'll try to get some pics up. You can replace the door handles WITHOUT having to remove the front windows.

I had to make some special tools:
Polish Aggie finger extension, and 10 mm wrench.

The backs take about 30 minutes a piece. The fronts will take about 45 minutes each.

I know I read posts about having to pull the windows to replace the fronts, but it can be done without all that work.

Tom

[TMKHUM]

All-

I'll try to get some pics up. You can replace the door handles WITHOUT having to remove the front windows.

I had to make some special tools:
Polish Aggie finger extension, and 10 mm wrench.

The backs take about 30 minutes a piece. The fronts will take about 45 minutes each.

I know I read posts about having to pull the windows to replace the fronts, but it can be done without all that work.

Tom

I need pics and directions on how to do this. I have been installing about three sets a week and its killing me! Please! BIG-C

White 03-H2-LUX

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</a>

[TMKHUM]

Alright, here are some pics and info.

[TMKHUM]

More pics

[TMKHUM]

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[TMKHUM]

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[TMKHUM]

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[TMKHUM]

Alright, see the pics above.

To remove the front handles you'll need the following:
10 mm offset box wrench with end cut-ouff
10 mm socket on a 1/4" drive ratchet (smaller the better)
Doublesided tape - Get the stuff they use to install mirrors (at Home depot, lowes)

Facing the door, interior side:
there are 3 studs securing the handle bucket.

The nuts on the left side, and on the upper side can be removed by using the cut-off wrench pictured. This is a tight squeeze but you manuever the wrench between the door skin and the window.

The nut on the right side can be removed with the ratchet. It is tight fit, but the ratchet will fit between the door handle and window track. To gain better access, you need to first disconnect the rod going to the lock assy.

For the install: From the pic above, you need to thread the nut on the right side stud (couple threads only). Also, you need make up the latch rod.

Now slide the handle bucket assy. into position.

Now, here comes the patent pending Aggie finger extender. Because of the space constraints, you can't spin the other 2 nuts on with your fingers. Here's the trick. Take a piece of double sided tape and stick the nut to your finger. You can then put the nut on the bucket stud, and spin it in.

Tighten everything up (not too tight!), reinstall the door panel.

Couple notes:
-I used a razor to cut thru the adhesive holding the foam/fiber baffle.
-Take your time and be careful, there are some sharp edges!
-You'll have to use both hands to to get the ratchet on the right nut/stud
-I used a punch to drive out the lock assy.-after pulling the retaining clip.

Hope this helps! Hey circuitguy, how 'bout a sweet deal on a fuel door

...and yes it took me three hours and helluva lot of cussing on the first front handle...the second one got done in about 30-45 minutes.

Have a good one, happy holidays

Tom

Wow, Sounds easy! Thanks for the info Tom, I have been killing my self installing these things. They are so popular but no one wants to install them! Drop me an email and Let me know what fuel door you want from my site so I can get to work for you on a price. BIG-C

White 03-H2-LUX

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</a>

[H2 Daddy]

Why didn't you just buy the adventure series in the first place?

[NSXTC]

How would the adventure series help? The door surrounds are still the same. It's the surround that most people get's changed out to chrome/billet and I do not believe it's available on any of the series. At least for 2003. Not sure about 2004?

Regards,
David
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H2SUT.com
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Red metallic, Lux package, Poron backup sensors, throttle body by-pass, Independent dual DVDs, Volant air box, DRL mod, chrome hood handles and latch.

Some people just want to change the black handle to the LUX chrome one. BIG-C

White 03-H2-LUX

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</a>

[H2 Daddy]

Oh, my mistake. I thought you guys were blacking out all the chrome.

[GasGuzzler]

This sawed-off wrench technique really works. I bought the buckets from circuitguy/G-style and got them installed without removing the windows in a single afternoon!

I saved $300. THX!