Repair / replace outside door handle on C3

[Dan D.]

Does anyoneknow where there might be a good detailed, illustrated instruction or a video on replacing an outside door handle on a C3. Thanks, Dan

[Kenn S.]

Re: Repair / replace outside door handle on C3

Personally, no, but there certainly might be something out there. However, I just removed a set and my memory is still relatively fresh if you have any faith in that. I'll write out the steps as I recall if you like. It's not terribly hard to do, but the rearward nut is tough, I'll grant. If I miss a step, no doubt someone here will fill it in.

[Dan D.]

Re: Repair / replace outside door handle on C3

Thanks Kenn. I would appreciate any help I can get. Sometimes a tip from someone who has done a job can make all the difference. I've taken the door apart before but I've not replaced the outside handle. I really don't know if something can be adjusted or it actually needs replacing. Probably sounds crazy, but just in case, I bought every part in there that I could think of. I can't stand getting something torn apart and then have to order and wait for parts...probably a serious defect in my personality. I will admit I have accumulated a few "spares" over the past 30 years. Anyway, thanks again and have a great day. Dan

[Kenn S.]

Re: Repair / replace outside door handle on C3

The editor is messing me up a little, so apologies for formatting. Hopefully this will turn out. Again, from memory, but it should be close... Hopefully helpful! There isn't much that is adjustable from the handle's end, BTW. I totally "get" buying the parts. I also pretty much refurbish or replace anything I tear down...it's been there 30 years, so why put cruddy parts back in?
1) Remove door panel
2) Remove door vapor barrier (at least the upper corner)
3) I found it helpful to remove the door latch screws to allow the latch mechanism to float...space is tight up there, and an extra quarter inch is helpful. Be careful not to chip the paint on either the door or screw heads.
4) If equipped, you'll need to remove the plastic anti-theft panel/plate (keeps someone from sticking a rod down through the window and jiggering the lock rod). There should be a small 5/16" screw/bolt at the door's rear and one underneath the vapor barrier. You'll find an access hole in the steel inner door frame for all of this work.
5) I removed the lock cylinder as I'm painting the door. I suspect you'll want to remove that as well. If a passenger door, the process is fairly simple--just remove the snap lock to loosen the cylinder, then twist the cylinder to remove from the lock rod. There should be a small clip holding the rod to the cylinder, but it's easily removed by pushing on the clip's prongs. If a driver's door and the car comes with anti-theft, there is an electrical connection that must be undone prior to twisting. Once removed from the lock rod, you pull the lock cylinder out from outside the door. (When reinstalling, it's a great time to clean old wax/polish and replace the gasket.)
6) You should now have access to the door latch, in tight quarters. You first have to remove the latch rod from the latch, which involves another simple hold-down clip. The rod is bent in an 'S' configuration, so just release the clip for now. Later you'll twist the latch to remove, but first the nuts (next step).
7) The fun part...there are two 7/16" nuts that hold the latch to the steel door frame, and you need to undo both. The forward nut can possibly be reached with a 1/4" drive and differential with an extension, but the rearward is pretty much undone using a wrench, so I used a wrench for both. You can get only 1/8 of a turn for most of the removal, so patience is warranted. You'll also probalby have to contort your body a little if you're strongly left or right handed, depending on the door you're working on. Just think of it as Corvette yoga.
8) With the nuts undone, pull the latch upwards slightly and turn to remove from the latch rod (the 'S' turn). Once you do, you should be able to pull the latch mechanism out entirely.
9) To reinstall, reverse the process. Don't forget a new latch gasket as well.

[Don L.]

Re: Repair / replace outside door handle on C3

FWIW, I've had mine (1972) out a few times. This is a really, really fun project. You're gonna love it!

The process I followed is almost exactly as Kenn has detailed so nicely. I think the only difference for me was that I used a 1/4" drive 7/16" swivel socket and extension for both nuts. You need the 7/16" swivel socket as a std socket with a universal swivel uses too much space, which is quite constrained in there.

Depending on which year you're working on, you might want to wash the silver paint off the inside if using repro parts. Originals were not painted under the "flap" and (I think) all repros are. Lacquer thinner will do the trick, but be sure to do it BEFORE you install the handle assembly.

Hope this helps!

[Dan D.]

Re: Repair / replace outside door handle on C3

My thanks to both Kenn and Don. I appreciate your responses.Anytime I'm doing something I haven't done before, I find that talking tosomeone who's done it, always helps. I've had my '72 convertible since 1985 soI've done and had done a few things over the years. New frame in '89...found abrand new frame in a GMPD warehouse...new top and interior...car still hasoriginal paint, chrome, glass and drivetrain. Anyway, thanks again. Dan

[Kenn S.]

Re: Repair / replace outside door handle on C3

Wow! You've actually done quite a bit, and more complex stuff than a door handle. I'm sure removing and restoring/replacing the handles will be a breeze. It's tight up in there, a knuckle-buster at times, but worth it to get those fixed back up. If it's a spring issue, you might be able to replace that (I don't car for the insertable metal strip spring idea, although I grant it would/should work). Not much to it once you get it apart. Do be careful with that paint...easily chipped when pulling the handle upwards. Best of luck!

[Don L.]

Re: Repair / replace outside door handle on C3

Wow! You've actually done quite a bit, and more complex stuff than a door handle. I'm sure removing and restoring/replacing the handles will be a breeze. It's tight up in there, a knuckle-buster at times, but worth it to get those fixed back up. If it's a spring issue, you might be able to replace that (I don't car for the insertable metal strip spring idea, although I grant it would/should work). Not much to it once you get it apart. Do be careful with that paint...easily chipped when pulling the handle upwards. Best of luck!

VERY good point and sound warning. I put blue painters tape around the handle's opening in the door before inserting the handle. You need to manipulate the handle a bit during installation, so if not extremely careful and without good protection, chipped paint is a significant risk. In fact, chipped paint is a likelihood as far as I'm concerned.

[Gary R.]

Re: Repair / replace outside door handle on C3

Good info on removing the handle, one thing I would recommend is to remove the latch and clean it with brake cleaner. Then lube it good and check the operation. Many times these get pretty dirty and you would be surprised how well they work with some cleaning and greasing. I use the white Lithium grease. You might want to buy an couple of the clips used for the outside rod and the adjusting rod nut on the latch arm.

[Steve L.]

Re: Repair / replace outside door handle on C3

The editor is messing me up a little, so apologies for formatting. Hopefully this will turn out. Again, from memory, but it should be close... Hopefully helpful! There isn't much that is adjustable from the handle's end, BTW. I totally "get" buying the parts. I also pretty much refurbish or replace anything I tear down...it's been there 30 years, so why put cruddy parts back in?
1) Remove door panel
2) Remove door vapor barrier (at least the upper corner)
3) I found it helpful to remove the door latch screws to allow the latch mechanism to float...space is tight up there, and an extra quarter inch is helpful. Be careful not to chip the paint on either the door or screw heads.
4) If equipped, you'll need to remove the plastic anti-theft panel/plate (keeps someone from sticking a rod down through the window and jiggering the lock rod). There should be a small 5/16" screw/bolt at the door's rear and one underneath the vapor barrier. You'll find an access hole in the steel inner door frame for all of this work.
5) I removed the lock cylinder as I'm painting the door. I suspect you'll want to remove that as well. If a passenger door, the process is fairly simple--just remove the snap lock to loosen the cylinder, then twist the cylinder to remove from the lock rod. There should be a small clip holding the rod to the cylinder, but it's easily removed by pushing on the clip's prongs. If a driver's door and the car comes with anti-theft, there is an electrical connection that must be undone prior to twisting. Once removed from the lock rod, you pull the lock cylinder out from outside the door. (When reinstalling, it's a great time to clean old wax/polish and replace the gasket.)
6) You should now have access to the door latch, in tight quarters. You first have to remove the latch rod from the latch, which involves another simple hold-down clip. The rod is bent in an 'S' configuration, so just release the clip for now. Later you'll twist the latch to remove, but first the nuts (next step).
7) The fun part...there are two 7/16" nuts that hold the latch to the steel door frame, and you need to undo both. The forward nut can possibly be reached with a 1/4" drive and differential with an extension, but the rearward is pretty much undone using a wrench, so I used a wrench for both. You can get only 1/8 of a turn for most of the removal, so patience is warranted. You'll also probalby have to contort your body a little if you're strongly left or right handed, depending on the door you're working on. Just think of it as Corvette yoga.
8) With the nuts undone, pull the latch upwards slightly and turn to remove from the latch rod (the 'S' turn). Once you do, you should be able to pull the latch mechanism out entirely.
9) To reinstall, reverse the process. Don't forget a new latch gasket as well.

What is a differential tool in the quote above" 1/4" drive and differential'?

[Terry M.]

Re: Repair / replace outside door handle on C3

What is a differential tool in the quote above" 1/4" drive and differential'?

I am pretty sure he is referring to a 1/4-inch flexible joint tool.