AWR-Fix: Door Handle Carrier Permanent Fix*

[Clavurion]

Originally Posted by andrewwynn

Don’t take offense not a swipe other than to point out, my fix is far better than new. It effectively eliminates the design defects of both the dhc (by tuning the brittle joint that breaks into a flexible joint with give) and eliminates the freeze condition of the actuator that sets up for breaking the dhc.

No worries. I appreciate you efforts on this matter and would have likely used teflon tape as a glide surface on lock mechanism if I had known this before. I already renewed the lock and handle over 3 years ago. Previously the lock froze many times and eventually the handle broke like they do. After replacing the parts I've not encountered frozen lock. Conditions here in Finland are cold and the vehicle is still parked without cover.

[Bmwe5320023.0]

Well I'd rather fix it once and never have it break again

I guess this tape should do it

Homend PTFE Coated Fabric Teflon Tape Adhesive Tape High Temperature Teflon Tape for Vacuum, Hand and Impulse Sealers Machine Sealing Tape 10M (1.97inch x 33feet(W*L)) https://www.amazon.ca/dp/B07XYT5VS1/..._m00tEbZYGBAQW

Can't you just use duct tape instead? It has great adhesive properties and is pretty slippery

[andrewwynn]

The fix for the actuator solves the problem of the actuator freezing which will regularly cause the break of the DHC. A brand new DHC can easily break when the actuator freezes.

I find the replace everything vs repair anything mentality tragic.

So: you are suggesting: spend $80-90 vs 8-9¢ for a repair that is not as strong? (Well with the steel zip tie I guess more like 30¢). You suggest that replacing a DHC with a new one gives some significant expectation of trouble free operation, which if used in a sub freezing environment, not true. I have seen a DHC break in less than two months from one good freeze.

If you live where it gets below freezing, mod your actuator so it won't freeze.

Mouse Feet mouse Skates DIY Teflon Tape Computer Gaming Mouse Replacement Feet Pads Cut By Yourself ,2 Sets https://www.amazon.com/dp/B01LZ44P6M..._og1tEb4PR7NFG

That's the fix tape I bought.

M-D Building Products 3541 M-D 0 V-Flex Weather-Strip with Adhesive Back, 17 Ft L X 7/8 in W, Polypropylene, 1 Pack, Brown https://www.amazon.com/dp/B000CSGEIW..._Zj1tEbH32589K

And I've also used this.

I tried a test with grease only, the ice that forms acts like a squeegee and scraped it off. I had better luck with a thin film of grease staying when the thin layer of Teflon or nylon between the steel and ice. The ice formed on the steel side but the grease acted as a water repellant and the ice left a tiny gap between the ice and the Teflon.

The force reduction to unlatch the frozen latch was on the order of 100x.

[andrewwynn]

I wouldn't use regular tape. The double sided adesive on the tape adds an insulation layer that helps keep the ice that forms from making a strong grip

[Bmwe5320023.0]

I just ordered those metal zip ties and got this teflon tape
https://www.amazon.ca/dp/B000CSGEIW/..._ye2tEbSG0BMBX

Since I'm in Canada, we've lately had weather swinging from -20C at night to 10C during the day...
Out of 4 doors I only have 1 that opens from the outside so I gotta fix it before I can't get inside the car anymore.

I'm really impressed with you dedication on this subject and all the time you've taken to fix this extremely common defect on X5.

I'll post your iCloud link for people to get a better idea of the operation. I'm very visual and found it very helpful

https://www.icloud.com/sharedalbum/#...B-A86CE10D45B8

[andrewwynn]

Last resort u you can open the tailgate and climb though*. If your window still opens you can roll the window down by holding the door key in the unlock position. (And open the door using the inside handle)

* Yes of course personal experience and my 80+kg was a damn tight squeeze over the back seat in the upright position. (I didn't want to have to take the cargo cover out)

Spray some silicone on the door seals every week or three over the winter or at least any time the temps drop through freezing when water is in the air. Remember is not liquid precipitation that freezes the door latch, it's condensation

Teach your passengers and yourself that if the handle feels stuck down do not pull forcefully, open the door from the inside and defrost the door by driving with the heat on.

[andrewwynn]

Note with the metal zip ties, to get them to pass through twice they need to be opened slightly. I think it's covered in my write up. Also since they lock differently than nylon (they lock as they pull open slightly), you can't really make them short tight so don't try, just plan to shim like done above.

Test in a vice if possible before reassembly, that's how I figured out I needed to double wrap the metal zip.

[aureliusmax]

this thread is very confusing, the detail photos are zoomed in so much i don't have a good perspective of the entire picture

[Bmwe5320023.0]

Ahaha good point! Didn't think about getting in through the tailgate lol!

Well I think with your mode it doesn't really matter if I pull on the handle or not because I ground off that little piece. If i understood everything correctly, the handle will kind of "dry fire" and won't break. Not only that, but with this mode the handle won't freeze. And it addition it is beefed up quite well. So pretty much break proof!
I'll be installing it today and hopefully I'll finally be able to open the door from outside.

[andrewwynn]

The problem that causes the break usually is if the actuator freezes. Cold alone won’t be a problem need a magic combination of high humidity and the actuator cold enough to condense water out of the air followed by the ambient dropping below freezing. It usually happens 2-3x per year in Wisconsin.

Another problem that can happen is the cable can get water inside and freeze and BMW revised the DHC to have a little rubber nipple at the top of the cable to help keep water out but that’s not the main freeze point.

It’s possible to spray the likes of windshield anti-freeze or WD-40 to prevent a freeze through the screw access hole on the end of the door. I will try to take a video to show this. I may already have one I forgot.

The problem is that’s a one time treatment not a cure. But if you know it just rained and is about to go below freezing, spraying down the hole (bend the end of the spray tube to spray straight down about 3cm in the hole, it should coat the arm that freezes up.