Now we can address the other issues involved with this car. There seemed to be a lot more plastic than we have seen before. After we removed this panel, we discovered foam covering over the whole door. The only thing we can see outside this foam are the speaker, the door handle cable and remote mirror controls.(See Photo 11).
We carefully proceed to peel this away from the door so we can access the doors inside panel. There is no way you can salvage ANY of this foam. The glue on the side is impossible to remove. We ended up tearing all the foam off.
Next, remove only what’s necessary in order to access the door lock and door handle. It is a very tight process and you need to do this in order as described here.
Inside this door panel are two door handle rods (Photo 12). The most obvious choice would be to remove the first one closest to you. Do not do this. Remove the second and hardest one first. We found that you have to pull the outside door handle in order to remove this black lock rod from the inside. By pulling the door handle, you raise the white rod out of the way to allow you to get the black rod off. When the door handle is static, it is in the way. (See Photo 13.)
Next, remove one nut holding the front part of the door handle.
We are now ready to remove the door handle. This turned out to be a little tricky. It is a very tight fit and we had to move it around quite a bit to get it out of there. Be patient it will come out (Photo 14). At first we thought something else might be holding the handle but there wasn’t. It just took a few minutes of moving it around to work it out. You can see on the label where we scraped it while working it out of the door (Photo 15).
On the left you can see where the rods attached inside the door panel. You have to pull the handle out to get to the back rod first, and then take the first and closest rod (Photo 16).
We will now get into taking the cylinder out of the handle. This turned out to also be a little complicated. First, remove the three Torque headed screws holding this portion of the handle together, shown in Photo 17.
There are several steps in the procedure. First, we used a long Torx wrench to get down into the screw, shown in Photo 18. Next we had to take the lock rod apart on the right side to get to the screw underneath there (Photo 19).If you could pull the door handle and still get to this screw, that will also work. This just seemed to be an easier way.
The left side of Photo 20 shows the screw we needed to remove. Take the lock rod out and then pull the plastic holder out. Once you take the rod off and remove the plastic, you will have access to the screw beneath, shown in Photo 21. Once the obstructions were removed, we can access the third and last screw.
The next step is to remove the outer housing of the door handle. You must depress a tab to pull this apart , shown in Photo 22. In order to depress the tab, remove the outer door handle from the lock cylinder assembly (see Photo 23). There are two pieces to this assembly when you remove it, but you only have to remove the outermost covering. As long as you can remove the cylinder once the back portion is off, you don’t need to remove anything else on the front side of the door handle. Once the three screws are removed, pull this part of the cylinder apart. This is one of several parts as you will see.
Disassembling the Cylinder
We will now draw our attention to the back side of the cylinder since this all has to be taken apart to get the cylinder out. The first part is the plastic lock rod holder. The key phrase here is “plastic.” You will have to proceed slowly so as to not break any of these parts.
Three prongs must be slowly worked off and over the end of the back cylinder. Carefully and slowly work each prong loose one at a time (See Photo 24). As shown in Photo 25 with all the prongs loose, the end slides off.
Now we need to remove a spring (Photo 26). The spring just comes out but the clip has to be pushed to grab a side of it to pull off.
The clip holding the cylinder can be pulled up with a small screwdriver and then pulled off (Photo 27.) This should now allow the cylinder to slide out of the housing (Photo 28).