Door Handle Fix

Ford Ka - Fixing a broken outside door handle (handle will not open door)

Basically the plastic handle is attached to the lock mechanism via a metal rod, the plastic linkage on the back of the door handle gets broken and can no longer open the door. I was quoted £120 to fix this at the dealers, so thought I would have a go myself. Some people had written guides about removing the door trim, but nobody had actually done a guide about fixing the door handle problem start to finish.

Tools Required

Screwdriver (philips star and flat heads)

Drill (4 / 4.5 mm metalwork drill bit)

Stanley Knife

2x 4mm rivets and a rivet gun (or self tapping screws)

silicone sealant (optional)

Step 1 : Remove door card and skin

Pop out electric window control with a flat screwdriver and disconnect from cable. Removed screw now visible in the hole.

Remove the other 3 screws from the door card..

Door card can now be removed, its held on with plastic clips that should pop off..

Now peel back the skin behind the handle area..

You should now be able to see the severity panel that protects the lock area, its riveted to the door in two places (see third pic top and bottom) and sealed with silicone (black in picture) at the side next to the door skin.

Step 2 : Remove security panel

Both rivets need drilled out, I used a 4.5mm drill bit. Then the silicone seal needs separated from the panel with a stanley knife.

Step 3 : Fit new handle and reconnect to lock mechanism

Unscrew old handle (you can see the linkage that is broken on the old handle). Attach linkage and screw in new handle.

Step 4 : Re-rivet and seal security panel and reattach door card

Re-rivet security panel to door using 4mm rivet (An alternative would be to attach using self tapping screws). Then reseal (this step could be skipped if necessary, but probably best to do it) using silicone sealant. Then reattach door card using the clips and 4 screws. Reconnect electric window controls and pop back in.