Door Handle Flap - Will Not Return to Original Position

86subaru2

NUMBER 12-35-86

APPLICABILITY ALL 1985 AND 1986 XT COUPE MODELS DATE 08-14-86


SUBJECT: DOOR HANDLE FLAPS


Should you encounter an XT Coupe with a door handle flap that will not return to original position, a weak return spring may be the cause.

This condition can be corrected by following these instructions for installing a new door handle flap return spring and new flap retaining pins.


Parts Required

Part Number Description

60103GA110 Flap Return Spring and Pin Kit

Tools Required

1 - 3/32" Drift Pin Punch 1 - Small ball peen hammer 1 or 2 - clean shop rags (to protect the parts during disassembly)


Step 1) Remove the outer door handle by following the procedure in the
1986 Subaru Service Manual Section 5-2, Pages 17, 18, and 21.

FIGURE 1:

Step 2) Using a small ball peen hammer and a 3/32" drift pin punch, tap
the door handle flap retaining pins inward to remove the flap from the handle. (See Figure 1).
NOTES: * Do not hit or scratch the painted door handle surfaces.

* Do not use excessive force when removing the door handle flap because it is plastic and can be broken.

* In extreme cold weather conditions the door handle should be warmed to room temperature before attempting repair.

FIGURE 2:

Step 3) Install the new spring by placing the bent ends through the
inner pin holes on the inside of the door handle flap. (See Figure 2).

NOTE: The banded tab of the spring should be installed away from the key lock cylinder side.
Step 4) Reinstall the door flap handle by:

* Placing the banded tab of the spring toward the inside shelf of the door handle.
* Press the door handle flap into position, * Install the retaining pin opposite the key lock cylinder side first, followed by the key lock cylinder side.



NOTE: Use only the new retaining pins provided, dispose of the old pins.

XT Coupe models manufactured on or after July 9, 1986 will have the new spring installed in production starting with these VIN's:
Step 5) Reinstall the door handle in the reverse order of removal.


This procedure can be claimed for vehicles within the terms of the Subaru Warranty using:

Operation # Time

One Outer Door Handle - R&R #B915-261 0.6 Hrs.
Each Additional Outer Door Handle - R&R #C915-265 ADD 0.5 Hrs.
One Door Handle Flap Spring and 2 new Pins


in each Handle #C915-271 ADD 0.2 Hrs.


Use Failure Code XDX-48