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Old 12-26-2015, 09:15 AM   #18
jakeru
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Join Date: May 2015
Location: Greater Seattle, WA
Posts: 534
When I replaced my inner door handle spring, I noticed the old spring had worn a groove in the end of the door handle where the spring mated. The grove would twist the hooked end of the spring each time the inner door handle rotated (eventually causing fatigue failure of the hooked end). I fixed this by removing the door handle from the door panel and filing the spring mating surface smooth using a small round file to eliminate the grove - shown in attached picture.

I also had to shorten the metal on the end of the hook a bit, so it would not bind on the mating door handle. This was easily done with dykes. (The spring metal was not that hard.)

Finally, I added a bit grease during reassembly to help the spring's hooked end to pivot across the mating surface of the handle with less friction (and hopefully, to prevent the new spring from wearing another groove in the mating surface).
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