Door Handle Problems

Last updated: January 18, 2000

Applies to:

• 1988-97 Oldsmobile Cutlass Supreme 2-dr
• 1988-96 Pontiac Grand Prix 2-dr
• 1988-96 Buick Regal 2-dr
• 1990-94 Chevrolet Lumina 2-dr

Why it breaks.
The door handle assembly is made of a brittle die-cast aluminum alloy, commonly referred to as "pot metal". It often breaks and causes the door handle to flop around loose. This is because the metal used to cast the door handle itself is too brittle, and over normal use, it will gradually weaken until it snaps.

Buy a new door handle.
Unless you have good welding skills, there is no way to repair the old door handle. The metal is physically broken. The door handle was available with two different types of finish, satin black, and gloss black. Be sure you buy the right kind. A brand new door handle will have a much better movement and feel than a used one from a junkyard, but can cost up to $40 more depending on where you buy it. As of late-1999, the retail price for a door handle is $75.70. Most dealerships will charge about that much, but others may charge more. My local dealer wanted $84 for one! Here are my door handle sources:

• Brand new Genuine GM door handle: Dal Slabaugh - $53.50+shipping (12/99).
• New aftermarket clone door handle: GCStilley@aol.com - $40 shipped within USA.

Replacement.
Replacing the door handle assembly is very easy. It is replaced from inside the door jamb behind the door handle itself. The door handle assembly is the entire unit, including the exterior pillar trim plate the door handle is mounted in.

1. Remove the plastic cover behind the door handle assembly by removing one black 14mm nut from just above the door handle, and 1 screw (usually phillips) from the bottom of the plastic cover.
2. Remove linkages from lock cylinder and door handle assembly. Use a small flathead screwdriver to slide retaining clips forward, and linkages will come free.
3. Remove one black 14mm nut from the very top of the door handle assembly.
4. Remove one phillips screw drom the bottom of the door handle assembly.
5. Door handle assembly should now come free by pulling out slightly at the top, and pulling upwards.
6. Transfer lock cylinder and key minder light (if applicable) to new door handle assembly. Lock cylinder is retained by a single TORX bolt.
7. Reinstall in reverse.

TIP: If you lose or damage any of those black plastic coated nuts, order new ones. They are GM p/n 10067214 and should be around $0.58/each. There are two on each door.

Preventing Door Handle Breakage.
Due to the brittle nature of the material used to make the door handle, the major key to keeping it from breaking is not to be too rough on it. Here are some tips that may really help:

• Stop pulling the door handle when the door opens. Many door handles I've seen are slightly bent out at the top due to being pulled a little past its end of travel.
• Don't try to "fix" a rubbing or warped door handle, or it will break. The door handle can't take much stress! Of course, if the rubbing of a warped door handle bugs you that much, and you don't care if you break it since you'd rather have one that works well anyhow, then go ahead and give it a try.
• When the door opens enough, pull the door completely open from a spot above the door handle. If you keep pulling on the door handle to open the door, it will bend ever so slightly over time, and eventually the top of the door handle won't rest against its rubber stop. After awhile, it will SNAP.

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