How I fixed the exterior door handle on my 1996 VW Passat TDI

			Pictures
			#1	Click for a bigger version
			#2	Click for a bigger version
			#3	Click for a bigger version

Please note: This page is highly UN-technical and not intended to be any sort of official recommendations. It's merely how I fixed a problem I was having with my 1996 VW TDI Passat. It should work on all b4 model Passats, which are (I think) from model years 1995, 1996, 1997 and 1998. If you try it and mess up your door, don't come after me. So there.

The problem: External door handles on B4 Passats tend to stop working. This is a gradual process, where at first it might take a couple of pulls to open, then more pulls, and finally it won't open at all. This leads to much angst, and there's just way too much angst in the world.

A possible reason: The roll-pin that holds part of the mechanism (what I'll call the "widget" ... clever, eh?) in place tends to slide out of position, allowing the widget to slide towards the outside of the door handle.

How to check: Follow steps 1-3 below to see if your roll pin has slid out and the widget has moved out of position.

How to fix it

1. Open the door and, using a Phillips-head screwdriver, unscrew the large screw (parallel to the door handle) at the back of the door. See #1 for a picture, or click here for a big picture
   Please note: It appears that the passenger-side doors are REVERSE threaded, so go the opposite ways to loosen/tighten the screw.
   
   
2. Pull out the exterior handle. It should slide forward, then out. See #2 for a picture, or click here for a big picture
   
   
3. The back of the mechanism should have a "roll pin" sticking out (see picture #2). If your problem is like mine, there will be a very small arm (widget) that should be in front of the pin (front being towards the front of the car), but has slid to the outside of the handle. You can tell which widget this is by pulling on the handle and seeing it move.
   Please note: The roll pin may have fallen out completely. If it isn't there, you can probably use a small screw or something in its place.
   
   
4. Pull the roll pin out enough so the widget can be slid into place (you'll notice a hole in the widget). Force the widget towards the interior of the car and line it up so you push the roll pin all the way through to the hole on the back end, then go ahead and push the roll pin all the way through to lock the widget into place. You might need a screwdriver or something to force it in, and perhaps a small screwdriver to force the widget into place. When done, it should look like #3.
   Please note: For best results, push the roll pin ALL THE WAY in.
   
   
5. Spray some lubricant (silicon gel works fine for me) on the interior of the door and the locking mechanism.
   
   
6. Re-assemble the door.
   
   
7. Open and close the door freely!