Just thought I’d ask for some quick advice. Where should I start in my
search of the archives re:
Broken left rear outside door handle (I know I asked before when I
sensed it was stiff and imagined it might break; now it has broken: oops.);
The HVAC system has gradually stopped working altogether. No fan at all.
I’ve glanced at Chapter 3 in the Haynes manual, but I need a place to
start. Recently, the fan would sporadically suddenly turn on and the heater
worked then. And previously the A/C worked as well. (The fuses seem OK.)
Here is a procedure that I used for making the door handle repair.
Al
89 XJ40 97K
My rear passenger door handle gave up the ghost. The problem was a cracked
pivot post on the potted metal housing that holds the handle. After
searching the archives, I was able to gain enough information to make the
repair by:
Bonding the cracked post to the housing with epoxy, then fabricating a U
shaped bracket between both pivot posts. (Small bracket found at the
hardware store.)
Secured the bracket by epoxy, then drilled a hole (#6 machine screw)
through the bracket and housing.
3)Epoxied a small piece of flat stock for extra strength on the under side
of the housing above the bracket and tightened with a #6 machine screw, lock
washer and nut. (The head of the screw from the underside of the housing).
Using the pivot post holes as a guide, drilled holes into both sides of
the bracket. (The pivot pin of the handle is now supported by the original
posts and the U shaped bracket as well as the material of the flat stock on
the opposite side of the housing)
Used a dremel tool to grind the bracket and flat stock accordingly to
provide free movement of the handle.
Touched up housing and new brackets with flat black paint.
This repair appears to be extremely strong and passed the acid test of my
kids operating the door handle. No matter how hard I try to tell them to
lift up on the handle, they inevitably pull then decide to lift.
Al
89 XJ40 91K
ps: After writing this post, it would sure be great if there was a common
repository to post photos of repairs.
Hello folks,
Just thought I’d ask for some quick advice. Where should I start in my
search of the archives re:
Broken left rear outside door handle (I know I asked before when I
sensed it was stiff and imagined it might break; now it has broken:
oops.);
>>>Here is a procedure that I used for making the door handle repair.
Where should I start in my search of the archives re: 1) Broken left rear
outside door handle
Thanks for the post. I want to take the cowards way out. I tried in vain
but also could not find some sort of ‘kit’ a vendor soetime back was selling
for XJ40 door handle repairs. Three are bad, one works like new–I want
them all to look like new.
Anybody know the vendor(s) that offer this kit?
Thanks,
Wayne Estrada Still Homeless Somewhere in the USA
1989 Vanden Plas (Alpine Green) w/Funky Door Handles
1989 XJ-S Convertible (Dorchester Grey)From: “Al LeGault”