trunk handle fix

e46nIt · Oct 25, 2005

Here's How I fixed my trunk handle with out buying a new Peice from the dealer ship

DIY price $5.00 Labor 1.5 hr

first you will need to Buy fast set epoxy, for plastic and metal, and get four washers or however many you need.

Tools used: torx socket, solder gun (recomended) , 3/16-1/4 drill bit depends on the size of the opening on the washer you intend to use, a popsicle stick for appling the epoxy, some blue tape and an exacto blade, and needle nose plyer.

Step one: Lossen and remove all Four Bolts

Second Step: place some kind of paper towel or old rag on the bumper to avoid and glue falling on th paint.

Third step: Place some tape around the hole, so the glue doesn't get on the foam padding

Fourth step: place your washer inside the housing, try to line it up in the center

fifth step: Using a solder gun, I placed it against the washer using a little pressure to heat up the plastic, allowing the plastic to melt and seet the washer. By doing this the washer can't move when applying the epoxy. I suppose super glue can work to, haven't tried it.

After I melted the plastic

Sixth step: Before applying the epoxy, roll up some paper to plug the washer hole. I only filled one hole at a time, because of the epoxy drying so fast. Apply the epoxy slowly until you reach level with the foam padding.

should look simialr to this

seventh step: Remove the tape, I used an exacto blade and needle nose plyers to remove it, sorry no picture. Then use a drill and drill out the paper rolled up in the center. Drill from the repaired side, so you don't scratch the paint.

Eighth step: Install, Tighten the bolts down evenly until totally snugged up. If the holes don't line up all the way. use a smaller drill bit and longate the hole to the right spot.

I saved allot of money, and its even stronger Now. Good luck

BMWPower06 · Oct 26, 2005

how did u disconnect the wires? i couldnt figure that part out.

AlBoston · Oct 26, 2005

i dont really understand what you did. what was the problem?

e46nIt · Oct 26, 2005

AlBoston said:
i dont really understand what you did. what was the problem?

this is what the factory part looks like before it breaks

Three out of four broke, do to someone trying to pull up on the handle, without pressing the button supplied under the handle. This is a picture of what it looks like broken

Hope I was more clear on my problem and the fix. Thanks

e46nIt · Oct 26, 2005

BMWPower06 said:
how did u disconnect the wires? i couldnt figure that part out.

I didn't disconnect the wire, I was able to Do it all attached. It would be easier to do disconnected, but I didn't feel like removing the trunk lid liner.

mzarolinski · Oct 26, 2005

seantito1 said:
this is what the factory part looks like before it breaks

Three out of four broke, do to someone trying to pull up on the handle, without pressing the button supplied under the handle. This is a picture of what it looks like broken.

Hope I was more clear on my problem and the fix. Thanks

I think if you reduce the size of the pictures we may have a better look at what is wrong. I am too lazy to scroll over.

espguy3 · Nov 30, 2005

Bravo!! nice DIY, Mine is a 2002 325Ci and its only being held on with one screw now... (damn extended warranty doesnt cover trim peices i guess)
I was just about to fork over $105 for a new one from the dealer and swap it out myself (unpainted, it was $200 something painted)..I thought I'd check out the e46 forums.. and boy am i glad i did... Now i'm gonna get some washers and epoxy and give this a try tonight..

Thanks
:clap:

wildpanda86 · Dec 29, 2005

Nice, mine just straight broke off on me while I opened the trunk. All four are busted. Stealership wants 88 dollars for a new handle and it is not even painted!!!

This is soo gonna help.

I'll try it out today:thumbup:

dirsh · Jan 22, 2006

Mine broke too. only 1 screw holding it on. I take it you have to replace the whole piece and have it painted? How is this fix holding up? I might try it myself. thanks for the DIY

espguy3 · Jan 22, 2006

Well I have to say mine is still holding up fine.. It feels solid still when i open the trunk. I did this fix on Nov30th so it's only been about 2 months but so far no problems. I was also worried about the epoxy, because it was like 30 degrees in my garage when doing it the epoxy was not the easiest to work with and I wasnt sure how well it would hold since i probably wasnt using it at the correct temperature, but no complaints so far.. saved me like $300 for the price of a new one painted..

wildpanda86 · Jan 23, 2006

I tried salvaging my old one by epoxying some new washers in... me and glue don't mix and it didn't even hold up for one day.

Bought a new handle from the dealership for around $90.00

Then I was able to seperate the original painted cover from the old handle... it is glued so you have to very carefully use a heat gun to pry it off... then I placed it on the new handle... that saved me from having to pay to get it painted & it turned out great!!!

I guess the problem with the handles breaking is that you have to wait for the electronic latch to disengage before yanking up on the handle which takes a split second. If you just pull up on the handle, you are putting alot of pressure before it releases. Just touch the pad and wait to hear the release, then pull up.

Orbital808 · Jan 28, 2006

SEANTITO1 you are the man! 3 of my bolts had broken loose and I was dreading going to the stealership to have my trunk handle replaced. I followed your DIY and $12 later my trunk handle is as good as new. It actually feels sturdier than before the bolts broke! Thanks for posting such an excellent DIY!!!

dirsh · Jan 29, 2006

What size washers did you guys use?

dirsh · Feb 22, 2006

I did the fix and it worked good until my friend pull it hard and it's coming off again.

I think i'm going to buy a new handle from the stealer and try to stick the cover on

e46nIt · Mar 21, 2006

Glad It worked out for some people. Thanks for checking it out. Mine is also still holding up great.

dirsh · Mar 21, 2006

I was about to buy another trim piece but then I messed around with it and got my button working. So I decided to try and glue the washer back in. It's better than my first try and seems to be more solid. The handle is not sitting straight though. Most people can't tell, but I can.

sergio · May 23, 2007

I'm going with the superglue gel type, according to spec it's the best for metal and plastic. I will melt some alumn ontop of washer to try and get more solids...stay tuned....

Sergio

trunk handle fix

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