Body - Exterior Door Handle Covers Loose/Missing
09-042September 8, 2010
Applies To:
2005-09 RL - ALL
Door Outer Handle Cover Is Loose or Missing
(Supersedes 09-042, dated November 6, 2009, to revise the information marked by asterisks)
*REVISION SUMMARY
Under WARRANTY CLAIM INFORMATION, the failed part number was changed.*
SYMPTOM
The front or rear body-colored outer door handle cover (end cap) is loose or missing.
PROBABLE CAUSE
The locking tab on the plastic door outer handle cover is breaking, causing the cover to loosen or fall off.
CORRECTIVE ACTION
Replace the loose or missing door outer handle cover.
PARTS INFORMATION
SPECIAL TOOLS
^ KTM trim tool set: SOJATP2014
^ Trim pad remover, Snap-on A177A or equivalent, commercially available
WARRANTY CLAIM INFORMATION
The normal warranty applies.
Failed Part: 72184-SJA-J11ZC
Defect Code: 06201
Symptom Code: 01201
Skill Level: Repair Technician
REPAIR PROCEDURE - FRONT DOOR HANDLE
NOTE:
Put on gloves to protect your hands.
^ Use the appropriate tool from the KTC trim tool set to avoid damage when prying parts
^ Take care not to scratch or damage the door panel or other interior trim pieces.
1. Fully raise the front door glass.
2. Using a trim tool, push on the bottom hook and pivot the cover on the upper hooks, detach the front hook, then remove the cover and the screw securing the inner handle.
3. Using a trim tool, pull the top edge of the pocket light cover out to release the hooks and the cover, then remove the screw.
4. Using a trim tool, pry out the notch of the grip cover to detach the hook, pull out the cover to release the remaining hooks, then remove the cover from the grip.
5. Remove the door panel with as little bending as possible to avoid creasing or breaking it.
^ Release the clips that secure the door panel with a commercially available trim pad remover.
^ While holding the door panel away from the door, disconnect the door subharness connector and the power mirror connector.
^ While holding the door panel away from the door, remove the screws, then remove the inner handle from the door panel.
NOTE:
The inner handle cable and the lock cable are connected to the door panel. Do not pull the door panel up too far, or the inner handle cable will be damaged.
REPAIR PROCEDURE - REAR DOOR HANDLE
NOTE:
Put on gloves to protect your hands.
^ Use the appropriate tool from the KTC trim tool set to avoid damage when prying parts.
^ Take care not to scratch or damage the door panel or other interior trim pieces.
1. Fully raise the rear door glass.
2. Using a trim tool, push on the bottom hook and pivot the cover on the upper hook, then detach the front hook, then remove the cover and the screws securing the inner handle.
3. Remove the rubber mat, then remove the screw.
4. Release the clips that hold the door panel with a commercially available trim pad remover.
5. Remove the door panel with as little bending as possible to avoid creasing or breaking it.
^ While holding the door panel, pull the panel upward to release it from the upper clips.
^ While holding the door panel away from the door, disconnect the door subharness connector and the power window switch connector, remove the screws, then remove the inner handle from the door panel
NOTE:
The inner handle cable and the lock cable are connected to the door panel. Do not pull the door panel up too far, or the inner handle cable will be damaged.
6. Using a clip remover, remove the remaining clips from the door. Using a knife, cut the bosses off the clips. Push each clip, then pull it away.
7. Peel back the upper left corner of the plastic inner door cover.
8. Disconnect the connector, and remove the screws, then lower the latch.
9. Remove the access cap, then push the glass run channel aside, as needed, to insert a Phillips screwdriver or a thin-wall 10 mm socket and extension onto the outer handle cover bolt.
10. While holding the outer handle cover from the outside of the door, loosen the bolt. Pull back on the cover to release its hooks from the outer handle base.
11. Install the rear door outer handle cover in the reverse order of removal, and note these items:
^ Make sure the outer handle rod is connected securely.
^ Make sure the door handle and the lock work properly.
12. Install the rear door panel in the reverse order of removal, and note these items:
^ Make sure the plastic inner door cover is installed properly and sealed around its outside perimeter to keep out water.
^ Before reinstalling the door panel, install the clips.
^ Replace any damaged clips or cable fasteners with new ones.
^ Make sure the window and the power door lock operate properly.
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