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3. Remove the outside handle.
Pop open the yellow linkage connector inside the door that goes from the key lock to the latch. It is far easier to do this while the housing is still screwed to the door.
The yellow linkage connector spins so make sure that the latch is spun towards you when you re-connect it for easy access should you have to disconnect it again. Disconnect the antenna wires from the housing. It is a connector that is clipped to the housing itself.
Also notice that I had just washed my car before this repair and notice the water inside the door. That’s why you don’t want to rip the rain shield.
Remove the black plug to access the angled torx screw that holds the key tumbler cover on (no pic of the plug). You will need to pull the outside door handle slightly to get it off.
DO NOT REMOVE THE SCREW FROM THE HOUSING. Screw it only far enough to get the housing off, that’s it.
If you look at the housing picture on the box you will see the angled torx screw and hopefully understand why it’s on an angle and how to get to it.
To remove the outside door handle you need to pull the handle outward half way, reach inside and hold the spring load by the black counterweight at the top, move the handle back flush with the door (unsprung), slide the handle rearward then out.
For future reference, IT DOES NOT REASSEMBLE THE SAME WAY! If you try to reassemble the same way you will break off the switch tips, requiring another housing! (don’t ask how I know)
4. Remove the housing
Once the handle is off the only thing holding the housing to the door is the outer torx screw. Remove the second screw completely. Hold the housing from the inside to keep it from falling down inside the door.
The housing itself should not be defective (unless it is physically broken) so even though you bought the whole “Housing K” assy. does not mean you have to replace the whole thing.
Just switch out the micro switches. They snap out easily. The key tumbler locking pin is a real mother to get off and back on again. (don’t ask how I know)
5. Practice re-assembly!
After it is disassembled, install the outside door handle into the housing with the old micro switches still in place as if it were on the door, to get a feel and to see how it re-assembles. Re-assembly consists of inserting the outer door handle into the forward and rearward slots of the housing, in the rearward position of the housing, flush with the housing, then snapping the handle forward. You do not need to hold the spring action counterweight to do this. The outside handle actually has a cam on it that will make the spring lever pop into position and will not touch the micro switches. Be sure to use enough white grease everywhere, that will assure smooth operation between the plastic-on-plastic action that occurs on every door opening, as you will see while you play with the 2 pieces.
6. Reassembly
This is done in reverse of the disassembly process except for the outer handle installation.
Also, when replacing the key tumbler cover you will need to apply a lot of force to the cover and apply a lot of force to the torx driver while turning the driver, otherwise the screw will miss the threaded hole of the cover.
Notice that the key tumbler is flush against the hole after it is tightened up.
Don’t forget to reinstall the black hole plug!
I hope this helps. Any additional tips are welcome. GOOD LUCK!
3. Remove the outside handle.
Pop open the yellow linkage connector inside the door that goes from the key lock to the latch. It is far easier to do this while the housing is still screwed to the door.
The yellow linkage connector spins so make sure that the latch is spun towards you when you re-connect it for easy access should you have to disconnect it again. Disconnect the antenna wires from the housing. It is a connector that is clipped to the housing itself.
Also notice that I had just washed my car before this repair and notice the water inside the door. That’s why you don’t want to rip the rain shield.
Remove the black plug to access the angled torx screw that holds the key tumbler cover on (no pic of the plug). You will need to pull the outside door handle slightly to get it off.
DO NOT REMOVE THE SCREW FROM THE HOUSING. Screw it only far enough to get the housing off, that’s it.
If you look at the housing picture on the box you will see the angled torx screw and hopefully understand why it’s on an angle and how to get to it.
To remove the outside door handle you need to pull the handle outward half way, reach inside and hold the spring load by the black counterweight at the top, move the handle back flush with the door (unsprung), slide the handle rearward then out.
For future reference, IT DOES NOT REASSEMBLE THE SAME WAY! If you try to reassemble the same way you will break off the switch tips, requiring another housing! (don’t ask how I know)
4. Remove the housing
Once the handle is off the only thing holding the housing to the door is the outer torx screw. Remove the second screw completely. Hold the housing from the inside to keep it from falling down inside the door.
The housing itself should not be defective (unless it is physically broken) so even though you bought the whole “Housing K” assy. does not mean you have to replace the whole thing.
Just switch out the micro switches. They snap out easily. The key tumbler locking pin is a real mother to get off and back on again. (don’t ask how I know)
5. Practice re-assembly!
After it is disassembled, install the outside door handle into the housing with the old micro switches still in place as if it were on the door, to get a feel and to see how it re-assembles. Re-assembly consists of inserting the outer door handle into the forward and rearward slots of the housing, in the rearward position of the housing, flush with the housing, then snapping the handle forward. You do not need to hold the spring action counterweight to do this. The outside handle actually has a cam on it that will make the spring lever pop into position and will not touch the micro switches. Be sure to use enough white grease everywhere, that will assure smooth operation between the plastic-on-plastic action that occurs on every door opening, as you will see while you play with the 2 pieces.
6. Reassembly
This is done in reverse of the disassembly process except for the outer handle installation.
Also, when replacing the key tumbler cover you will need to apply a lot of force to the cover and apply a lot of force to the torx driver while turning the driver, otherwise the screw will miss the threaded hole of the cover.
Notice that the key tumbler is flush against the hole after it is tightened up.
Don’t forget to reinstall the black hole plug!
I hope this helps. Any additional tips are welcome. GOOD LUCK!