Getting Inside the Doors to Replace the Failing Exterior Door Pull Gaskets, to fix latches, locks, window lifts, or modify check-straps

Getting inside the door cavity is part of the process to fix latches, locks, window lifts, and check-straps.  The below procedure is to replace the pull handle gaskets. The process includes how to get into the door cavity for any number of other servicing items. 

Getting inside the door cavity:

• Pull the interior door card, which requires a Phillips screwdriver and an Allen Hex key, Remove all the Phillips head screws and finish washers on the door card, door pocket, and surrounding the speaker box for Premium Sound equipped cars. There are a lot of them, note their size, length, and position for reinstallation later;

• For Premium-Sound equipped cars remove the speaker box cover and the speaker box Phillips head mounting screws, unplug and remove the speaker box;

• Remove the Phillips screw inside the door pocket holding it to the door pull handle frame.

• Remove the larger Phillips screw underneath the forward-most part of the door pull-handle frame that holds the frame in place at the front of the door;

• Release the interior door pull rod by pulling on the interior door release paddle and reaching behind it and slipping the rod off its attachment to the backside of the paddle

• Unscrew the two large recessed socket head capscrews holding the interior pull handle frame. They are deeply recessed in the two holes in the frame behind the pull handle paddle.

• Lift off the door handle frame;

• Remove the door card while unplugging the door speaker harness for non-Premium Sound cars.

• Slit the plastic door cavity sealing film behind the door card to reach into the door cavity. Make more than one slit to facilitate ease of access for later steps. When done working, seal up the slits using clear packing tape. Trying to pull the original cavity sealing film back from its edge to avoid putting a slit in it tends to be problematic when trying to put it back in place when you are done;

Removing the rain shroud that covers the lock mechanism & door pull mounting nut:

• Remove the two very small Phillips screws in the latch side (B Pillar) door's jamb facia. These very small Philips screws hold an internal plastic rain shroud over the interior lock mechanism. The shroud hides the latch mechanism and also needs to be removed to gain access to the exterior door pulls mounting nuts;

• Removing the shroud can take a while and it requires some flexing to remove and reinstall. Take your time flexing the shroud, and eventually, you will get it out and later back in position so it can be reattached with the two small screws.

Servicing the exterior pull-handle, lock cylinder or handle mounting gaskets:

 

The two gaskets you will need to order are 993-537-621-00 and 993-537-631-00 one each for each door left or right.

• Remove the two small hex nuts on the interior of the door to release the pull handle from the door skin. No biggie. Put a rag in the bottom of the door cavity to avoid losing one of the nuts if your hand slips. The M5 nut is part number 900.380.001.02 in case you lose track of one.

• Use a good amount of masking tape on the outside of the car to tape the exterior door pull in place so when released it doesn't fall to the floor and get damaged. It might be a good idea to put a piece of carpet below the door on the floor in case the tape fails.

• Once the nuts have been removed the door pull simply lifts off the exterior door skin, pull, lever & Lock cylinder mechanism all in one piece. 

• 

  Keyway Cap/Plug

  Once the door pull is detached its casting cavity and the lock cylinder mechanism can be cleaned of accumulated debris, the mounting gaskets can be replaced, the pull reinstalled and the door buttoned back up.
• As a finishing touch, the little black plastic keyway cap /plug
  for the outside of a 993 door handle can be purchased under part number 993.537.613.00

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Door

Door Panel

Inside

Door Card
Door Speakers

Door Lock