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Disassembling Porsche 996 door panels

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Old Aug 29, 2012 | 06:28 PM
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Disassembling Porsche 996 door panels

Disassembling Porsche 996 door panels
- Removing the door panel from the car is fairly simple; there are only a few screws to complete this process. The screws are found behind the piece that read “AIRBAG”, behind the door handle and inside the pull handle. You must pop the front side of the pull handle off in order to get to these two bolts. After taking these four bolts out pry the panel starting from the bottom. There are little white pins that pop the panel onto the door frame. You must pop these pins out in order to get the panel to come off. Once that is done pry upwards on the panel to pop it out from the top track. You should now have the panel hanging by two wire clips and also the metal rod that opens and closes the door. Take the wire clips out and the metal rod. The door panel is now free from the car.

- In order to separate the pieces of the door panel you must cut each of the melted rings on the back side of the door panel. I used a dremal tool in order to do this. I used a round grinding wheel and grinded off each melted ring. There are also melted tabs at the bottom of the door panel, first grind off the map pocket and then do the tabs because, under the tabs is a felt and you must peal that back in order to get the remaining tabs that are needed to separate the bottom of the door panel. Once all this is done you will now be able to separate the entire door panel. Take the spring off the door panel connecting to the door handle (don’t lose this as it is simple to do) and then you will be able the pry the center out of the panel.

- Once you have your panel wrapped it is time to re-assemble the door panel. Start with the top side of the door panel. I went to walmart and picked up some little screw and washers, I took the screws and washers and screwed them into the panel where the old melted rings used to be. Once that is all complete take the bottom half and double-side stick tape it to the top panel. I suggest not skipping this step or the gluing process might be a little difficult. Then take some epoxy glue for plastic and mix it all together and then dab it into each melted tab that was cut out. I also ran it down the seam of the two panels to make sure it was nice and tight. Once this is dry it is then time to screw the map pocket back on. Be very careful with this step because it is easy to screw through the front side of the panel. Once it is screwed in use some epoxy to secure the top section. The glue does not take long to dry at all so you will be able to re-install the panels 15-20 min after applying the epoxy.

- Re-install the panel by doing the reverse of step one

I am sorry I was not able to take pictures of this process but, if anyone has any questions please feel free to contact me. If you would like a write up of how I wrapped the doors I can also do that upon request. I hope this helps everyone
 
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