Door handle problem - Pontiac Solstice Forum
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post #1 of 7 (permalink) Old 07-26-2016, 12:57 PM Thread Starter
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Door handle problem

Just this morning I went to open my driver's side door and when pulling the door handle to open the door the whole mechanism starting pulling out of the door. By whole mechanism I'm referring to the portion containing the key lock. This portion of the door handle should be anchored solidly to the door, mine is starting to pull out when I pull on the door handle. No warning this was loosening up as you would get with a bolt and nut working loose so I'm thinking a "C" clip or something similar has let loose. Am I opening a whole can of worms if I take the inside door panel off? Or is this a job best left to the dealership?
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post #2 of 7 (permalink) Old 07-26-2016, 01:11 PM
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This is a well known failure. There are three 10mm bolts that secure the handle to the door. The two on the rear end of the handle are known to fail on a regular basis.

You can remove the door inner and by removing the three retention bolts remove the door handle. Many, including myself, have used JBWeld epoxy to repair the handles. I repaired one after the threads failed and the other three before they actually failed.

You can buy improved Cobalt handles on line. The newer units are reinforced structurally to help with this problem, but can fail if not reinforced with JBWeld.

If you take it to the dealer they will charge you full retail for the handle (same part number with same failure rate) plus the labor to do the install.

See many threads on this subject for more information.

Rob the Elder

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http://www.solsticeforum.com/forum/f62/punisher-65168/
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post #3 of 7 (permalink) Old 07-26-2016, 03:09 PM
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The door handle on the right is the area that bust, the door handle on the left is the reinforced version. GM used the non-reinforced handle on several models (cars listed below), and it also comes in an unfinished black version. Meaning it has several different part numbers.



I purchased some unfinished black Cobalt door handles last year and had them painted gloss black to match my car. I thought I had bought the reinforced version but did not, and per RTE suggestion used JBWeld to reinforced the handle.


Watch these videos to get an idea of how to remove and replace door handles. I'd say the most important tip is once you pull the door panel is do not let it drop. There's an inside interior door handle cable you have to be somewhat careful with. When you remove the door handle bolts either have magnetic socket inserts or do what I did after I dropping bolts a few times, I used chewing gum to help keep the bolts in the socket. Hey it worked.
https://www.youtube.com/watch?v=qkjuy1zbjNA

https://www.youtube.com/watch?v=sQWZxdLYAbI

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Mr & Mrs ChopTop's 09 Fastback & 06 Vert Mods thread:http://www.solsticeforum.com/forum/f...session-75468/ Original join date; Oct 2005 under LowLife handle.

Last edited by ChopTop; 07-28-2016 at 04:27 AM.
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post #4 of 7 (permalink) Old 07-27-2016, 07:05 PM
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I remember that one.

When you remove your original handle you will see the necessity for the JB Weld in filling the area surrounding the barrel nuts. Follow procedures and all goes well,don't drop the bolts.
Completely eliminates failure of new handle. While your mixing the JB you might as well repair the center consoles cracks.
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post #5 of 7 (permalink) Old 04-17-2017, 08:27 PM
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Quote:
Originally Posted by ChopTop View Post
The door handle on the right is the area that bust, the door handle on the left is the reinforced version. GM used the non-reinforced handle on several models (cars listed below), and it also comes in an unfinished black version. Meaning it has several different part numbers.



I purchased some unfinished black Cobalt door handles last year and had them painted gloss black to match my car. I thought I had bought the reinforced version but did not, and per RTE suggestion used JBWeld to reinforced the handle.


Watch these videos to get an idea of how to remove and replace door handles. I'd say the most important tip is once you pull the door panel is do not let it drop. There's an inside interior door handle cable you have to be somewhat careful with. When you remove the door handle bolts either have magnetic socket inserts or do what I did after I dropping bolts a few times, I used chewing gum to help keep the bolts in the socket. Hey it worked.
https://www.youtube.com/watch?v=qkjuy1zbjNA

https://www.youtube.com/watch?v=sQWZxdLYAbI
I ran into a loose door handle, so I just have to bump this post!

The two video's listed above were invaluable to my understanding of how to remove the door panel AND what & how to fix the problem. Thanks to all contributors.
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post #6 of 7 (permalink) Old 04-17-2017, 09:38 PM
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Welcome. I have had both cars door panels off multiple times and have posted oics each time on the Punisher thread

Rob the Elder

Punisher's Daddy
Green Dragon's chief mechanic
Carol's husband for 48 years

Secretary Rocky Mountain Solstice and Sky Club
Punisher's story
http://www.solsticeforum.com/forum/f62/punisher-65168/
Punisher thread index
http://www.solsticeforum.com/forum/f...ml#post1765649

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post #7 of 7 (permalink) Old 04-20-2017, 05:53 PM
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My coupe curbside handle was not loose at the rear of the handle, but was loose on the front of the handle. So it appeared to be a fix of just removing the door panel and putting a socket on the bolt head and tightening.

I may have missed it on the video, but I recall the video mentioning only a 7MM socket. It turned out the socket for the three bolts holding the handle were 10MM. After finding the correct socket size, it was a simple fix of just tightening the front bolt. It did, however, take about a 6 inch socket extension to reach the bolt head and tighten.

For now, the two rear handle bolts are secure, so an easy fix this time. However, a future fix may involve the JB Weld route.
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