DIY: R&R Door Handle and Lock Cylinder

[psst97]

Have seen this pop a few times recently so i figured I could post something up. Needed to pull one of mine anyway. If you have anything to add or correct, let me know. A few initial pics.

Fount out why the alarm system didn't work:


Also found out why the handle would lock but not un-lock:


Be sure to check this pin to make sure it's still there and not fallen out. Common problem why these handles stop working.


Tools Needed
Flat Head Screwdriver
Phillips Screwdriver

Handle Removal
1. Remove Door Card
2. Unplug Harness


3. Unscrew Phillips Screw (Driver Side Silver Screw - Counter-Clockwise, Passenger Side Black Screw- Clock-Wise)



4. Slide Handle Forward



5. Pull handle out swinging forward

6. Removal Success!

Lock Cylinder Replacement
1. Remove C-clip


2. Remove Upper Cam Plate and Spring


3. Remove Lower Cam Plate



4. Insert Key


*If no key for cylinder, support back side of handle and lightly tap out with hammer*


5. Remove Cylinder


6. Insert New Cylinder


7. Replace Lower Cam Plate - Align tab with tab on handle


8. Turn upper Cam Plate upside down


9. Hook Spring in one side


10. Bring other hook over tab and hook on the opposite side


11. Add Cam Plate to assembly aligning its tab with others


12. Make sure spring is on either side of all 3 tabs


13. Hold lock cylinder in place and align c-clip


14. Secure c-clip rest of the way

15. Done! Make sure you have tension in both directions with the key inserted. If not, you most likely installed the spring on the upper cam place incorrectly.

Handle Install
1. Fish Wire Through Hole
2. Slide front part of handle in


3. Swing handle into door


4. Slide Back into place


5. Tighten Screw (Drivers Side - Clock-wise, Passenger Side - Counter clock-wise)


6. Attatch Plug and Clip



7. Re-install Door Card

[perickomx]

nice write up!!

was doing this few days ago, not replacing the cylinder but yes, i have not the pin on position anad needs to improve.

thanks man.

[ellocolindo]

The only suggestio to this thread; will be to find a link to the b3 handle repair for the white color plastic thing that wears over time; it contacts the door rod inside the door and works the latch itself.
It is seen in a few pictures here.

[BenT Syncro]

Nice write up. Word of warning on aftermarket handles. They worked fine for me but the lock cylinder is not compatible with the original handle. If you don't mind having multiple keys, it's no biggie. If are as anal as me with keys, you may need the services of a locksmith to key alike.

Besides having different ends, the aftermarket cylinders have single wafers vs. double in the factory handles.

[x9t]

I replaced my front door handles and I swapped my Old cylinder lock into them.. I was hard at first because my cylinder lock was so old and the lube was dried.. I had to clean it off with a pick.. relube it and then it went into the aftermarket handle..

Nice write up.. when I searched.. not one person said anything about unclipping the connector.. or that you had to cut into the insulation to get at it.


JT

[crsmp5]

well no key and hammer breaks switch.... you MUST HAVE KEY... else do not plan on plugging switch in else it will roll windows down or up for you and screw with the alarm too...

[BenT Syncro]

I replaced my front door handles and I swapped my Old cylinder lock into them.. I was hard at first because my cylinder lock was so old and the lube was dried.. I had to clean it off with a pick.. relube it and then it went into the aftermarket handle..

JT,

There is probably more than one brand of aftermarket handle. Bought mine from a fellow in Latvia via eBay. The cylinders have totally different ends. I'm fairly familiar w/ VW locks of that vintage.

I wanted to add that the U-shaped white plastic bushing/escutcheon (not sure what to call it) visible on the large hole for the handles in pic#9 & #27 must be present for the handle to properly operate. It keeps the large end of the handle from wobbling. I've repaired a few Passat B4 and Jetta Mk3 non-working handle problems by simply replacing that clip. Care should be taken on installing as they are a PITA to fish out of the door once the door cards are in. Don't ask how I know. The ends of the 'U' have a channel intended to hold them to the sheet metal of the door. I find slipping it over the bottom first works best.

[97XJ2]

Also found out why the handle would lock but not un-lock:

Anywhere to get these individually? Or some sort of janky fix? I finally tore apart my driver side door handle and found out why I've had to unlock it from the passenger side.

Owned the car a month now and if its not one thing it's another so far.

Oh, and thanks for the write-up.

[x9t]

.. I have my old ones.. you can have them. Just pay shipping?

JT

[psst97]

.. I have my old ones.. you can have them. Just pay shipping?

JT

There ya go! I dont have any extra peices as all the handles I have are actually good.

[urban tribes]

All I have left is to figure out how to get into my locked, shut driver's side door

[97XJ2]

.. I have my old ones.. you can have them. Just pay shipping? JT

PM inbound

[B4 Slapshot]

Really Good write up. I replaced mine today with one I bought on GAP. I had to adjust my latch to get it to work and right now I am running a two key set up because being in college I can't afford to keep my car unlocked and unattended for more than a few minutes.

Favorited for the Future.

[psst97]

I ran into a weird issue this weekend. All handles and locks had been working flawlessly. We got our first snow and it got super cold and both front doors locks froze up. Door pin acted like it wanted to pull up but it wasnt happing. I had to jimmy the lock to get into it and once the temp came up above freezing it was fine.

I have had the latch freeze after being opened so the door wont close but never this. Makes it really difficult to get into the car....

[henrik77]

great write up

I am having problems with the new lock central locking system working
I changed a whole new handle and swapped the lock cylinder

my next plan is to just swap the pin over to the old handle
but now i and can't get the handle out
has anyone else run into this
Thanks
Henrik

I

[dewkie]

I had the same issue with th central locking trigger breaking off. I bought an entire handle and ran into the issue of my old locl cyl not matching up with the new handle internals. Newer cyl has 7 pins whereas the old cyl had 10. I had to swap my old pins into the new cyl. Starting from the keyhole side of the old cylinder if you ignore the 3rd 6th and 9th pins and then place the rest into the new cyl in order everything comes together pwrfectly. You have to clean the old pins with a toothbrush and some alcohol or they stick from all the crud and lube.

I am kinda glad I ran into the non fitting issue, now the only thing in my handle that isn't new are the pins.

I have to do my pass handle this week maybe I'll take some pics of the diff cyl and swapping the pins

[FdoVag]

Excellent How-to

Just be carefully because your window will break de wires again

You have to attach the wire inside too ... hard to explain, just look inside. sorry for my bad english

[BCampbell]

This is awesome. Today the driver's side lock on my '97 stopped unlocking with one turn of the key, but I can still unlock it via vacuum with two turns. Probably the same problem as in the 2nd pic?

My passenger handle has been fcuk'd for a while, I guess it's time to open up both doors. Anyone have any hints on the best way to source new handles? Thanks!