Broken cable on door handle - Kia Forum
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post #1 of 24 (permalink) Old 12-15-2011, 09:53 AM Thread Starter
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Unhappy Broken cable on door handle

I have 2005 Spectra. The wire or rod connecting to the door handle on the
driver side has broken off. Now I can only ope the door by rolling down the
window and ope the door from outside handle. I bought the rod and took apart the door panel and plastic cover. How do I remove the door module assembly to connect the rod. Connecting the rod on the door handle is simple, but I don't know how to remove the door module. Please help and
if you have pictures, that would also help. Thank you. Oh by the way
this is my first thread. Thank you all. Charlie

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post #2 of 24 (permalink) Old 12-15-2011, 02:05 PM
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There are three large black counter sunk Phillips bolts on the edge of the door (by the latch). Removing them will allow you to gain access enough to attach the cable.
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post #3 of 24 (permalink) Old 12-16-2011, 09:09 PM Thread Starter
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Hi Dave.

Thank you. I'll try that and see if it works.
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post #4 of 24 (permalink) Old 12-30-2012, 11:48 PM
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Hey Charlie...you may have already fixed your handle, but if not...I just did this job today. It is a pain and I totally can relate to the window down to get out of the car...err..embarrassing...anyways...

The 3 black screws mentioned in Dave's post will not even come into play with this job.
  • Remove the interior panel (this is easy to find on the internet...several hidden screws and pop out parts-don't get too frustrated - just take your time and pop out slowly since it may be cold where you are and you could accidentally break the little pop pressure screws.)
  • You'll have to peel the plasticy water barrier off gently at the edges with the super sticky black bead of sealer from the left to about mid door.
  • The green cable is the one you'll replace and the snap locks on the part you are replacing are tricky...just use a small flat head screwdriver and unsnap them to the side (you'll see how when you're in there looking at it
  • Unsnap the pink lock to the side THEN pull the cable out-unless it's snapped at that end like mine was.)
  • There is a black rubber ball end on the green cable that you'll put your finger behind and pop out towards you...be careful with this on the new one once it's connected so you don't break the braided cable
.

Now it gets a little more complicated but hang in there...I plan to try and post pictures of the parts you are working on since half the job is blind behind the metal.
  • There is a little black box to the left of the door...on the opposite side from you in the center of that black box will be a gold screw (you will realize that only once its out lol) the best tool to use that I can think of is a craftsman z (41315 wf)...its a z shaped tool with Phillips head on one side and flat head the other...they are at. Local sears for about 10 bucks but shouldn't be much more than that if any.
  • Unscrew the center screw
  • It will not remove that entire box but will allow for you to unsnap that black box's cover...see pics.
  • It will not come completely off and this part of the job is tight.
  • I will show you a pic of what you are touching inside there and it will make sense what to do...I figured this out on my own since there wasn't much on the internet to help
  • Unsnap the pink cable locks (identical to the one at the handle)
  • Carefully unsnap the rubber stopper that is identical to the one up at the handle...now you are free to remove that cable (there are little snap clamps to keep the black and green cables together...remove those and leave them hanging on the black cable for future use.
  • Start working backwards to install the new cable
  • Reattach the water seal plastic to the black glen and reassemble your door
  • Try it and make sure it works...there is a possibility of placing the rubber stopper to the left of the door to not seat right...it happened to me and I reached back in and fastened it properly and voila
!

Really hang in there...it is tedious but rewarding...I went 2 years rolling my window down...SOOOOO WORTH THE TROUBLE!! PC's to come when I load them up...

Gig <><
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post #5 of 24 (permalink) Old 01-01-2013, 02:28 PM
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Sorry Charlie...

I started an album on my profile with instructions and steps to go with pictures but the forum only allows 5 pictures...can't figure out how to add more...I put them on this reply as an attachment...again 5 pic Max...the attached are steps 1-5... I will try to reply wit 5 pics on each...frustrating.
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post #6 of 24 (permalink) Old 01-01-2013, 02:51 PM
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Steps 6-9...

I will post the instruction list that matches the pictures on the last pic post...
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post #7 of 24 (permalink) Old 01-01-2013, 03:03 PM
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steps 10-13

Next...lol
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post #8 of 24 (permalink) Old 01-01-2013, 03:13 PM
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steps 14-17

More pics...almost done...they should be in order the way I am posting them...
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post #9 of 24 (permalink) Old 01-01-2013, 03:25 PM
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steps 18-21

Hang in there...this will be the biggest post ever lol! I think this is it...leave questions but I think I hit everything...here is a copy of the instruction list that goes with the pictures...
1. Handle with broken cable.
2. Pop out rubber stopper from fixture.
3. Popped out.
4. Entire part for mental reference. (I was fortunate enough to have gotten the entire part from a salvage yard)
5. More of the part you will be working with from your sight limit (here are the 3 black bolts Dave was referring to but you will not need to touch at all)
6. This picture shows you what you can't see from the other side so you know what you're feeling when getting that gold screw out of the middle of this black cover box.
7. The tool I used and recommend for this job.
8. Removing the screw...remember righty tighty but backwards.
9&10. Places where the black cover will pop from..you cannot remove this piece completely but will be able to get between it to work on the cable.
11. How to gain access to the able work area.
12. View from the other side of the part container...the snaplock piece is identical to the handle side...you will unsnap downwards (opposite for install-but the install is easier than the removal-less painful on the fingertips)
13. Unsnapped and popped out...half done!!!
14. The little clamp holding the cables together...separate fro the middle...weird little clips.
15. Part out! Start working backwards with the new cable.
16. Snap the cover back in place and screw it down with the little gold screw. 17. Place the other end of the cable in the handle.
18. Pop in the rubber stopper.
19. Snap the pink snap lock over new end.
20. What it should look like completed.
21. Snap the cable clamps back together and into the door again.
22. Before reinstalling the panel...test getting out from the inside to ensure the rubber stoppers are seated in their proper spot.
23. If it works CONGRATS!! YOU NO LONGER HAVE TO EXIT THE CAR BY ROLLING THE WINDOW DOWN!!
24. Replace all remaining parts the way you removed them including the plastic water seal and panel and you are done! Enjoy!
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post #10 of 24 (permalink) Old 06-24-2013, 08:16 AM
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Door latch cable

I was looking at the pictures on how to replace the green door latch cable very helpful. is it possible to get that black box out of the door or just remove the gold screw and work blind, its hard to see inside the door
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