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Old 01-30-2010, 02:34 PM   #1 (permalink)
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Door Handle Part numbers - Broken Door handle fix

Hi,

So this happened to the sky thurs, found these threads about it but found no mention of actual part numbers for corresponding models with the same handle p/n's listed........so I did some investigation work:

I made a few phone calls and found what dealers had door handles in stock then went to my local Chevy and Saturn Dealerships to compare.

I found the chevy cobalt door handle options to be reinforced at least and quite a bit cheaper at that.


Chevy Impala ones were the same, but chevy also wanted 90 bucks FOR THOSE???

Saturn Dealer had the original chrome door handle for $91 bucks - nothing changed, same weak sauce door handle.


ALL DRIVERS SIDE P/N:
Saturn Part number:
Chrome OEM - non reinforced - P/N 25865676 - $91.00

Chevy Cobalt part numbers:
Black primered unit - ready for paint - P/N 25963384 - $55.03
Chrome unit-Identical but reinforced - P/N 25869324 - $46.29

PASSENGER SIDE P/N:

Chevy Cobalt part numbers:
Black primer'd unit reinforced - ready for paint - P/N 25963347 - $53.26 (with key hole)
Black primer'd unit reinforced - ready for paint - P/N 25963362 - $54.60 (with out key hole)

Chrome unit - Identical but reinforced - P/N 25869322 - $59.79

Pics to compare: - see the "bridges shown in red squares connect the nutserts"

Cobalt Black primer'd and Chrome reinforced:

I also must add that the black primered unit - the reinforced plastic "bridges" are about a milimeter thicker than the chrome "bridges"


Got it fixed myself Friday morning in under an hour including trip to the dealership.

As for install, I can probably add pics later but I just followed the interior door panel removal: Kappa Specific Sound Deadening Kits

Then used a 10mm socket to remove three bolts in order to remove the door handle.

You have to peel back the interior plastic on the door to gain access then reach back in there so that you don't drop the bolts.

I used a wobble extension (about a 8 inch one) and a 10mm socket and my handy dandy dewalt impact driver but a ratchet will work just fine....

See here:




The black primer'd handle was intriguing - paint match or a satin black handle paint job might look good!!! hey its an option for those that didn't know about it??

Some to compare the black primered option and the oem chrome handle:



I hope the part numbers above help someone get through this headache quick and less costly than the Saturn dealership charges for the same weak sauce door handle.....


-J

Threads i found on the subject:
Fist-full of Door Handle
Door handle question?
Door Handle Failures
Attached Thumbnails
Door Handle Part numbers - Broken Door handle fix-pic_0098.jpg   Door Handle Part numbers - Broken Door handle fix-dis_06.jpg   Door Handle Part numbers - Broken Door handle fix-differences.jpg   Door Handle Part numbers - Broken Door handle fix-pic_0103-supports.jpg  

Last edited by jasontamu; 03-27-2010 at 04:30 PM.
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Old 01-30-2010, 02:39 PM   #2 (permalink)
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More pics:





I would rate the install as a 2 of 10 in difficulty. Its quite easy and doesn't take long. So I would say anyone with the tools and patience can do this easily

Frustration level of even having to have to do this in the first place - 10 of 10

-J
Attached Thumbnails
Door Handle Part numbers - Broken Door handle fix-pic_0104.jpg   Door Handle Part numbers - Broken Door handle fix-pic_0105.jpg   Door Handle Part numbers - Broken Door handle fix-pic_0099.jpg  

Last edited by jasontamu; 01-30-2010 at 02:42 PM.
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Old 01-30-2010, 02:51 PM   #3 (permalink)
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Are they the same on both sides?
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Old 01-30-2010, 02:53 PM   #4 (permalink)
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Quote:
Originally Posted by DURAMAX View Post
Are they the same on both sides?
EDIT - UPDATED....ABOVE WITH P/N

-J

Last edited by jasontamu; 03-27-2010 at 04:32 PM.
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Old 01-30-2010, 03:18 PM   #5 (permalink)
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Thanks. They look like a lot better part. I may just get a pair and save them just in case as who knows if Government Motors will survive. The government could not even make money with the Mustang Ranch when the IRS took it over.
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Old 01-30-2010, 04:19 PM   #6 (permalink)
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Thanks. They look like a lot better part. I may just get a pair and save them just in case as who knows if Government Motors will survive. The government could not even make money with the Mustang Ranch when the IRS took it over.
No problem man!

Ya i would get a pair extra to had i known about this issue.....I plan on going back now and ordering a passenger side for the same reason.

I also think that even though its reinforced - a blob of adhesive/epoxy super hold would be good all in the cavities around it. Filling it in to add strength.

regardless of the cobalt reinforcements - its still a weak sauce design compared to other handles ive seen.........its plastic! geess....

-J
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Old 01-30-2010, 04:29 PM   #7 (permalink)
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$72.75 shipped for 2 at GM direct.
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Old 01-30-2010, 04:32 PM   #8 (permalink)
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That's a nice write-up there aggie with good pics! Have a set already body color matched and am waiting for a handle to fail before installing them. Just aheads up on the Cobalt replacements; some years/models (can't remember which) have no keyhole on the passenger side door handle.
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Old 01-30-2010, 04:33 PM   #9 (permalink)
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The ones on my 03 pick up are plastic too. I have yanked on them real hard when snow freezes the door shut and they have never broken. These are just a stupid design. I saw someone on the sol forum suggest that pushing on the lock cylinder with your thumb at the same time may reduce the force on the bolts.
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Old 01-30-2010, 04:43 PM   #10 (permalink)
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Quote:
Originally Posted by DURAMAX View Post
$72.75 shipped for 2 at GM direct.
nice.....not bad at all...

Quote:
Originally Posted by SkyVue2 View Post
That's a nice write-up there aggie with good pics! Have a set already body color matched and am waiting for a handle to fail before installing them. Just aheads up on the Cobalt replacements; some years/models (can't remember which) have no keyhole on the passenger side door handle.
ha..ha..ya its the A&M Engineer in me.......plus, i do write ups on a much more technical level fixing problems like this everyday at work....

great info on the passenger side door handle key hole! Thanks, ill keep that in mind......ill post the p/n's when i get mine....

Quote:
Originally Posted by DURAMAX View Post
The ones on my 03 pick up are plastic too. I have yanked on them real hard when snow freezes the door shut and they have never broken. These are just a stupid design. I saw someone on the sol forum suggest that pushing on the lock cylinder with your thumb at the same time may reduce the force on the bolts.
Yes, i agree, it is a weak sauce design.......its a plastic handle with metal nutserts in them with little reinforcement...

Most of the door handles i have seen are at least a cheap aluminum cast...

I agree, using your thumb to hold down the lock cylinder would definitely eliminate the issue, as thumb position would be exactly where the bolts are tied into on the handle..... doing that is definitely smart...

-J
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Old 01-30-2010, 10:48 PM   #11 (permalink)
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same part?

Looks like this is the same part# - Service Component - Door Handles - Front 25869324 - Crate Engine Depot and on sale for $31 each - might be good to have just in case.
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Old 01-31-2010, 01:44 AM   #12 (permalink)
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I agree, using your thumb to hold down the lock cylinder would definitely eliminate the issue, as thumb position would be exactly where the bolts are tied into on the handle..... doing that is definitely smart...
Sigh.....the things we do to keep from breaking our SKY.

1. Place thumb on lock cylinder to avoid yanking handle off the door.
2. Keep wheels centered when parking to avoid cylinder locking.
3. Close door before lower buttresses to avoid window rub.
4. Put small towels on top when closing trunk to avoid marring.
5. Open/Close hood with doors closed to avoid damage.
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Old 03-18-2010, 02:20 AM   #13 (permalink)
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good info. just ordered a pair from ced cause my passenger side broke, and i dont even use that side much!
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Old 03-18-2010, 03:14 AM   #14 (permalink)
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Quote:
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Sigh.....the things we do to keep from breaking our SKY.

1. Place thumb on lock cylinder to avoid yanking handle off the door.
2. Keep wheels centered when parking to avoid cylinder locking.
3. Close door before lower buttresses to avoid window rub.
4. Put small towels on top when closing trunk to avoid marring.
5. Open/Close hood with doors closed to avoid damage.
6. Hold beer between legs to avoid breaking cup holders.
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Old 03-19-2010, 12:57 AM   #15 (permalink)
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Please sticky this thread. It'll save the next door handle victim a lot of time & aggravation.
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