Hyper
03-28-2013, 10:14 PM
The BMW 8-series is subject to stress fracture in the door handle mechanism, potentially making it impossible to open the door using the outside handle.
The zinc-alloy is overstressed by the return spring for the exterior handle and/or forces created in output arm operating the latch.
Depending on your particular casting and how many operations, the zinc pivot will break sooner or later. But it will break. Both sides.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh00fractureoninputarm1_zpsd6598832.jpg
Replacing the stock cast zinc-alloy pivot with my brass pivot solves the problem by creating a continuous axle that much resists the axial twisting force of the return spring while allowing it to provide the torsional force it was designed for.
The latch actuator arm is sturdier than the original and is in brass, rather than cast zinc.
*** Tools ******
The 15/64 drill bit is the british/imperial version of 6mm metric. This is included as part of the kit until further notice.
The trim fork is highly recommended and I will look into providing this as a cost-extra item.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh00toolrequirements1_zps9f3532dd.jpg
Drill bit: Removes original rivet. Opens up the forward hinge to axle diameter.
Tape: Protects the outside handle from scratches.
Hooked pick: Pulls out the latch rod from its nylon holder.
Glasses and flashlight/torch: For seeing close up into the dark abyss.
Socket and drivers: For two nuts mounting DH frame, and lock nuts on axle.
Trim fork: Door panel/card.
Hammer and punch: Optional. Knocks out a stubborn original rivet.
Pliers: Grabs the return spring. Immobilizes the axle while turning lock nut.
*** Other supplies ***
It would be nice to have door panel clips on hand.
It would be thoughtful to replace the exterior handle trim gasket.
*** Do it *****
The battery does not necessarily need to be disconnected. But there are options.
Step one, apply protective tape to your outside handle. Then...
Doorlock stem.
Door panel screws hidden behind plastic plugs. Qty 3. The two behind the door pull seem to well captured in a plastic cavity behind the vinyl leather.
Although I've always gone to an effort to extract the screws, 50-50 chance that they are perfectly happy hanging out in their cavity while you remove the panel.
If you do elect to let them remain in their cavities, then tape over the hole on the panel so there will be no doubt about whether the screws are still there.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh02trimplugs1_zpsb776e9d8.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh03trimscrew1_zps21c6e6b0.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh04trimscrew2_zps610104ed.jpg
Use trim fork to pop the 10 clips on panel. Sixty percent chance you will break at least one clip.
If you must be rude, use a screw driver in place of the trim fork.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh05trimforkatwork1_zps154086b1.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh06panelcliplocations1_zps728fbe87.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh07typicalpanelclip1_zps173ba1e7.jpg
Use trim fork to pull back from 5 clips along window ledge...
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh05trimforkatwork2_zps959e5c72.jpg
as shown in this look-ahead.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh08nakeddoor1_zps99b514ba.jpg
Lift outward from the door. DO NOT lift up, or this will happen. You've now been warned.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh09doorpanelupperclip1_zpsb7b05ecc.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh10doorpaneltearout1_zps46a89fc3.jpg
Unhook the inside actuator cable and 4 electrical cables. Set your door panel/card aside in a impenetrable protection bubble.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh11insidelatchcable1_zpsc5dff5c0.jpg
Inside the door, push the trim retainer bar fowarded. Trim tabs should line up with slots in the bar, thus releasing the exterior trim.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh12trimretainerbar1_zpsf73079f9.jpg
I have foolishly forgotten to tape up my door handle. Note also the gasket which you will thoughtfully replace on your own initiative.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh13exteriortrim1_zpseb1f624e.jpg
Ideally the window glass is in its top most position. Three options:
1) do the procedure with the window in the dropped position,
2) close the door and disconnect the battery,
3) fool the door into thinking its closed, by manually clicking the latch into the closed position.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh14latch1_zps0f10ebdb.jpg
In two out of the three options, the glass ends up in the up-most position, and the forward bolt is then easily accessible.
DO NOT operate the door handle while you have a socket wrench on this bolt. Bad things might happen. You've now been warned.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh15forwardbolt2_zpse91282a7.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh15rearbolt1_zpsf94e5ce6.jpg
Here is where the actuator rod comes down from the door handle mechansim to operate the latch.
Before moving the door handle too far out of position, you will need to pull the lower end of this rod out of the nylon bushing.
A hooked pick tool, an angled allen wrench or needle nose plier will do.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh16actuatorrod1_zps20169077.jpg
At the forward edge of the door handle assembly are 1 or 4 connectors.
I typically disconnect these, however it occurs to me that a cleverer person could do the pivot swap right next to the door if you had a work platform at just the right height.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh17cableconnectors1_zps46cad179.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh18connectors1_zpsfbd65b34.jpg
*** Zinc pivot removal *****
At the forward hinge there is a rivet that is drilled out. The rivet is very soft aluminum.
A well placed finger will keep it from spinning, or use pliers.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh19rivet1_zpsead1b9d4.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh19drillrivet1_zpsd0973c69.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh19drillrivet2_zpsd8fad207.jpg
The rivet steps down below 6mm as it passes thru the forward hinge.
The reason for this step is so that the rivet can be secured in place without clamping down on the arm from exterior handle, leaving it free to rotate.
(Until further notice) the kit will includes a threaded rod and the forward hinge on the frame must be drilled to 15/64 (aka 6mm) to accomodate.
Later kits might transition to a bolt that steps down as the original rivet did, thus eliminating the need to drill the frame.
If the 15/64 bit is required, it is included in the kit.
DO NOT attempt to drill the frame with anything other than 15/64 or 6mm bit.
Since the frame is of very soft aluminum, operate the drill chuck manually but DO NOT turn on the drill motor. You've been warned.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh20drillframe1_zps7c6d425a.jpg
To remove the orignal zinc pivot, the return spring must be released from the exterior handle and from the step in the frame.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh21stockspringremoval2_zps61b59371.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh21stockspringremoval1_zpsf81731f6.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh22stockspringremoval2_zps43e83be1.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh23stockcomponents1_zps5453f280.jpg
While we're here, see how the spring coverts its return force into a twist on the handle input arm. This one is was ready to snap any day.
It would be wise to replace zinc pivots even though they have not snapped yet.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh24twistedshaft1_zps671ac078.jpg
The zinc-alloy is overstressed by the return spring for the exterior handle and/or forces created in output arm operating the latch.
Depending on your particular casting and how many operations, the zinc pivot will break sooner or later. But it will break. Both sides.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh00fractureoninputarm1_zpsd6598832.jpg
Replacing the stock cast zinc-alloy pivot with my brass pivot solves the problem by creating a continuous axle that much resists the axial twisting force of the return spring while allowing it to provide the torsional force it was designed for.
The latch actuator arm is sturdier than the original and is in brass, rather than cast zinc.
*** Tools ******
The 15/64 drill bit is the british/imperial version of 6mm metric. This is included as part of the kit until further notice.
The trim fork is highly recommended and I will look into providing this as a cost-extra item.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh00toolrequirements1_zps9f3532dd.jpg
Drill bit: Removes original rivet. Opens up the forward hinge to axle diameter.
Tape: Protects the outside handle from scratches.
Hooked pick: Pulls out the latch rod from its nylon holder.
Glasses and flashlight/torch: For seeing close up into the dark abyss.
Socket and drivers: For two nuts mounting DH frame, and lock nuts on axle.
Trim fork: Door panel/card.
Hammer and punch: Optional. Knocks out a stubborn original rivet.
Pliers: Grabs the return spring. Immobilizes the axle while turning lock nut.
*** Other supplies ***
It would be nice to have door panel clips on hand.
It would be thoughtful to replace the exterior handle trim gasket.
*** Do it *****
The battery does not necessarily need to be disconnected. But there are options.
Step one, apply protective tape to your outside handle. Then...
Doorlock stem.
Door panel screws hidden behind plastic plugs. Qty 3. The two behind the door pull seem to well captured in a plastic cavity behind the vinyl leather.
Although I've always gone to an effort to extract the screws, 50-50 chance that they are perfectly happy hanging out in their cavity while you remove the panel.
If you do elect to let them remain in their cavities, then tape over the hole on the panel so there will be no doubt about whether the screws are still there.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh02trimplugs1_zpsb776e9d8.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh03trimscrew1_zps21c6e6b0.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh04trimscrew2_zps610104ed.jpg
Use trim fork to pop the 10 clips on panel. Sixty percent chance you will break at least one clip.
If you must be rude, use a screw driver in place of the trim fork.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh05trimforkatwork1_zps154086b1.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh06panelcliplocations1_zps728fbe87.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh07typicalpanelclip1_zps173ba1e7.jpg
Use trim fork to pull back from 5 clips along window ledge...
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh05trimforkatwork2_zps959e5c72.jpg
as shown in this look-ahead.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh08nakeddoor1_zps99b514ba.jpg
Lift outward from the door. DO NOT lift up, or this will happen. You've now been warned.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh09doorpanelupperclip1_zpsb7b05ecc.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh10doorpaneltearout1_zps46a89fc3.jpg
Unhook the inside actuator cable and 4 electrical cables. Set your door panel/card aside in a impenetrable protection bubble.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh11insidelatchcable1_zpsc5dff5c0.jpg
Inside the door, push the trim retainer bar fowarded. Trim tabs should line up with slots in the bar, thus releasing the exterior trim.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh12trimretainerbar1_zpsf73079f9.jpg
I have foolishly forgotten to tape up my door handle. Note also the gasket which you will thoughtfully replace on your own initiative.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh13exteriortrim1_zpseb1f624e.jpg
Ideally the window glass is in its top most position. Three options:
1) do the procedure with the window in the dropped position,
2) close the door and disconnect the battery,
3) fool the door into thinking its closed, by manually clicking the latch into the closed position.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh14latch1_zps0f10ebdb.jpg
In two out of the three options, the glass ends up in the up-most position, and the forward bolt is then easily accessible.
DO NOT operate the door handle while you have a socket wrench on this bolt. Bad things might happen. You've now been warned.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh15forwardbolt2_zpse91282a7.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh15rearbolt1_zpsf94e5ce6.jpg
Here is where the actuator rod comes down from the door handle mechansim to operate the latch.
Before moving the door handle too far out of position, you will need to pull the lower end of this rod out of the nylon bushing.
A hooked pick tool, an angled allen wrench or needle nose plier will do.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh16actuatorrod1_zps20169077.jpg
At the forward edge of the door handle assembly are 1 or 4 connectors.
I typically disconnect these, however it occurs to me that a cleverer person could do the pivot swap right next to the door if you had a work platform at just the right height.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh17cableconnectors1_zps46cad179.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh18connectors1_zpsfbd65b34.jpg
*** Zinc pivot removal *****
At the forward hinge there is a rivet that is drilled out. The rivet is very soft aluminum.
A well placed finger will keep it from spinning, or use pliers.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh19rivet1_zpsead1b9d4.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh19drillrivet1_zpsd0973c69.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh19drillrivet2_zpsd8fad207.jpg
The rivet steps down below 6mm as it passes thru the forward hinge.
The reason for this step is so that the rivet can be secured in place without clamping down on the arm from exterior handle, leaving it free to rotate.
(Until further notice) the kit will includes a threaded rod and the forward hinge on the frame must be drilled to 15/64 (aka 6mm) to accomodate.
Later kits might transition to a bolt that steps down as the original rivet did, thus eliminating the need to drill the frame.
If the 15/64 bit is required, it is included in the kit.
DO NOT attempt to drill the frame with anything other than 15/64 or 6mm bit.
Since the frame is of very soft aluminum, operate the drill chuck manually but DO NOT turn on the drill motor. You've been warned.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh20drillframe1_zps7c6d425a.jpg
To remove the orignal zinc pivot, the return spring must be released from the exterior handle and from the step in the frame.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh21stockspringremoval2_zps61b59371.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh21stockspringremoval1_zpsf81731f6.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh22stockspringremoval2_zps43e83be1.jpg
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh23stockcomponents1_zps5453f280.jpg
While we're here, see how the spring coverts its return force into a twist on the handle input arm. This one is was ready to snap any day.
It would be wise to replace zinc pivots even though they have not snapped yet.
http://i236.photobucket.com/albums/ff166/PhantasticPhoto/BMW/HandlePivot/bmwdh24twistedshaft1_zps671ac078.jpg