Body - Exterior Door Handles Inop. In Freezing Temps
57 Door cannot be opened from outside handle in cold weather
57 12 63
2020051/4
March 15, 2012.
Supersedes Technical DIAGNOSIS AND REPAIR Group 57 number 11 - 44 dated February 16, 2011 for reasons listed below.
Affected Vehicles
144
Condition
Door cannot be opened or closed from outside the vehicle in cold weather.
Technical background
A plastic burr on the bearing bracket can cut the outer sheathing material of the Bowden cable. As a result, water can enter through the outside door
handle and into the sheathing of the Bowden cable. In extremely cold weather, it is possible for the Bowden cable to freeze. In this condition, the
door-opening function of the outside door handle may intermittently or consistently be inoperative until the vehicle is allowed to warm.
When the vehicle is entered through a different door and moved to a location where it can be warmed, the outside door handle becomes operative.
The functionality of the inside door handle is not affected by this condition.
Production Solution
Remove all plastic burrs from the bearing bracket and apply a protective fabric cover over the cable to prevent the cable from being cut.
Service
145
1. Obtain a new exterior door handle bearing bracket assembly, which includes the Bowden cable.
The part number revision has not changed for the reworked parts. Improved parts will eventually be introduced with a new part number revision.
2. Determine whether the replacement part is reworked. The reworked parts are indicated by two green dots near the cable attachment point on the
bearing bracket.
^ If two green dots are present on the replacement parts, then proceed to step 3.
^ If no green dots are present on the replacement part, then the following two steps must be performed:
a. Check the bearing bracket for any sharp plastic burrs or sharp edges. Round the edges and remove any burrs with a small metal file.
146
b. Apply a protective fabric strip around the Bowden cable where it touches the bearing bracket.
3. Replace the exterior door handle bearing bracket assembly, including the Bowden cable.
Tip: It is not necessary to replace the door lock mechanism, nor is it necessary to replace the interior door handle Bowden cable.
Warranty
147
Required Parts and Tools
Additional Information
All parts and service references provided in this TSB are subject to change and/or removal. Always check with your Parts Department and service
manuals for the latest information.
