Rear door handle carrier changed now door won't open.

[ix&x5]

I closed the door and thought I had it all together except for interior door panel now the handle or the inside latch won't open the door. Any Ideas?

[andrewwynn]

The repair manual is very specific about the Bowden cable being the exact length so the first thing to figure out is if the end of the outer cable is clipped in a the right place. Some have two grooves and it will clip in at the wrong place.


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[Qsilver7]

Originally Posted by andrewwynn

The repair manual is very specific about the Bowden cable being the exact length so the first thing to figure out is if the end of the outer cable is clipped in a the right place. Some have two grooves and it will clip in at the wrong place.


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Thanks for this tip...I'll be attempting this DIY real soon...and this made me go back to the video (that was posted in the other thread) and pay close attention to which groove the cable was clipped into:

• (pic 1 below - old carrier)
• (pic 2 below - new carrier)
• (pic 3 below - new carrier)

[andrewwynn]

Bingo exactly what I was talking about. Also: how the cable attracted to the inner handle matters. I've missed the attachment and had a dry fire situation


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[xbimma]

Originally Posted by ix&x5

I closed the door and thought I had it all together except for interior door panel now the handle or the inside latch won't open the door. Any Ideas?

The Bowden cable was my first thought when I saw this post. But OP said the door is not opening from outside and inside if I understood correctly. So I thought there must be something else going on.
Last time I changed the outside door carrier I actually drove the car two days without door carrier because of fitment issue (taped gaping holes). I was still able to open the door from inside however. I hope I’m wrong and perhaps OP could share more details.

[ix&x5]

Here's an update. The bowden cable is in the right groove. It all works until I lock the doors and then it won't open from the outside or inside after I activate the door locks(lock/unlock). I have to take the bowden off and the arm it attaches to is able to go down a bit further, and then I reattach the cable and it all works until the x5 is locked and then unlocked and it does not open. Take the cable back off, the arm goes down another 1/2" and reattach and it works again. This is a Trucktec from FCP. Anybody have an experience yet with these?

[andrewwynn]

Sounds like a manufacturing tolerance problem. i would be looking into possibilities of adjusting the length of the cable. Since there is no adjusting it would mean adding a notch or bending metal

[xbimma]

Originally Posted by ix&x5

Here's an update. The bowden cable is in the right groove. It all works until I lock the doors and then it won't open from the outside or inside after I activate the door locks(lock/unlock). I have to take the bowden off and the arm it attaches to is able to go down a bit further, and then I reattach the cable and it all works until the x5 is locked and then unlocked and it does not open. Take the cable back off, the arm goes down another 1/2" and reattach and it works again. This is a Trucktec from FCP. Anybody have an experience yet with these?

I suspect the door lock actuator is on its last leg. Would be easy to replace since it sits next to carrier. Pretty rare double whammy possibly going on. Is there some history with that door you aware off?

EDIT: check the fuse to door lock actuator before replacement

[ix&x5]

I was thinking the same. when I took the door apart I could tell someone had had it apart before that's all I know, even though I have 90% of the receipts. No locking issues before the handle stopped working one day and it was broken in the weak spot on the shaft pivot.

[ix&x5]

I got the new lock mechanism from FCP for $225 and I still had the same problem. I got the idea to take the old bowden cable off the old one and put it on the POS Trucktec carrier I bought from FCP and it solved the problem but am very unhappy with the Trucktec product. I had the new carrier in and out about 10 times before I decided the length of the new cable on the new carrier was the issue now I have a new $225 latch that I did not need. Not my first carrier rodeo either since I replaced two on the front door before.