BMW E90 Door Strap (Interior Door Handle) Replacement

macmaverickk · 07-07-2015, 02:39 AM

This is a rather simple DIY for a pretty common "sticky handle" problem with those of us in warmer climates.

There are a couple ways of securing your new handle to the panel (besides having a dealership do it)... this is my way which worked out very well and I'm obviously taking no responsibility for people ruining their handles or burning their houses down.

With that being said, let's jump into it!

Items needed (In order of appearance):
1) 2 hours of free time (Which is more than you'll need)
2) Prying tools (For door panel)
3) Torx 20 Wrench (Also for door panel)
4) Diagonal cutting pliers (aka Dykes)
5) Dremel Tool (OPTIONAL... just makes things a bit easier)
6) A second person (Someone stronger than you OR someone you trust with the next item on the list)
7) Torch (Yeah, it gets that extreme)
8) Any kind of metal rod (Vague, I know... It's for the step where we're melting down part of the handle and reshaping the plastic... I used a butt-end of a ratchet... the butt-end of a chisel could work well also)
9) New Handle (it's comprised of two parts... No more than $30 total... no nuts or bolts to worry about either)

STEP 1:
Take off the door panel. I'll let YouTube take care of this step for me.
THIS VIDEO is good. Obviously stop watching once the door panel is fully removed and speakers are disconnected (At minute 3:55)

STEP 2:
From the back of the panel, you can start working away at the melted plastic of the undesired handle:

I found that using a Dremel tool with a hollowing tip made it easier for my dykes to hold onto and rip the plastic apart.

STEP 3:
Once most of the overlapping plastic is cleared, you should be able to just pull the handle straight out. May require some wiggling and forceful pulling (Keep your mind out of the gutter!)

Out with the old, in with the new (Yes, I accidentally broke the old handle when taking it apart)

STEP 4a:
Alright, flip the puppy back over and you're going to want to get this up on a counter (needs to be well ventilated area like a garage). Also get something to support the other side of the handle, as there will be a lot of force coming down on it soon. See the plastic "prongs" from the new handle sticking out?

Yeah, get your metal rod, torch, and assistant nearby... This is where it gets fun.

STEP 4b:
Get your torch on a very low setting and hold it between 1-3 inches away from your first plastic-pronged victim. It also helps to concentrate the flame on the shaft of the plastic prong too (Not pictured).

After about 5-10 seconds of melting, have another set of hands forcefully crush the prong straight down with the "metal rod".

You'll have to cycle between heating and pressing around 3-5 times per plastic prong. Once it is mostly crushed, start to s p r e a d the plastic around to give it a good base. Check the handle to see if there's any wiggle room... cause there shouldn't be (Remember, this piece is pulling the WHOLE door by itself.

IMPORTANT NOTE:
Do NOT directly heat your metal rod and use that to crush a cold plastic prong. Not only will the rod quickly get way too hot to handle, BUT the plastic will actually STICK to the rod, which the opposite effect of what we want. Do not worry about catching the panel on fire when warming the prongs, it's not at flammable as it looks. But obviously exercise caution and minimize flames.

STEP 5:
Put the panel back on the the reverse order that you took it off! Put the lock switch thing in at the top (no idea what you call it) first, and I started with the prongs at the top of the door, and then just hit the door all around the trim until all the snaps stopped. Screw in the Torx 20 screws, then snap on the second piece of the handle, and finally snap the trim into place!

That wasn't so bad! If anyone else has used a different method of securing their door handle to the panel, definitely share your experience!!

BeastMode335i · 07-11-2015, 09:26 AM

Nice, thanks for the DIY.. I don't have these handles but I'm sure many will appreciate your tips..

mrmcheung · 07-27-2016, 08:54 PM

Thank you so much for this detailed DIY! Going to give it a shot as soon as I get the parts - do you have any recommendations as to where to find them according to your price range? I don't see any inner door pulls for less than $39.99

macmaverickk · 08-03-2016, 09:53 AM

Quote:

Originally Posted by mrmcheung

Thank you so much for this detailed DIY! Going to give it a shot as soon as I get the parts - do you have any recommendations as to where to find them according to your price range? I don't see any inner door pulls for less than $39.99

You're welcome!!

I think I just did a Google search of the part numbers... I ended up getting mine at ECS Tuning

opjose · 08-05-2016, 05:08 PM

Out of curiosity:

Could you have cut the new handle's plastic inserts flush from the back, then threaded a bolt and washer to both hold it in place and make it removable in the future?

Were there any obstructions preventing someone from doing so?

Thanks.

marvel.marv · 08-13-2016, 01:15 PM

Hey!

It's much better to use a soldering iron just like this:

Just heat it up and push it into the prong.

You can cut 1/4 inch from the top of the iron if you wanna be extra careful to not go to the other side.

cdgatti · 11-06-2016, 12:36 PM

wonder if an electric heat gun could be used for this instead of the torch?? Would it be hot enough to melt the plastic? BTW this sure seems like a dumb design by BMW not making these just bolt in and out.

ucdbiendog · 11-09-2016, 01:37 PM

Quote:

Originally Posted by marvel.marv

Hey!

It's much better to use a soldering iron just like this:

Just heat it up and push it into the prong.

You can cut 1/4 inch from the top of the iron if you wanna be extra careful to not go to the other side.

I also used a soldering iron for this job, but used a flat blunt tip. worked quite nicely.

kugarek · 11-02-2018, 05:22 AM

Wow this is a very detailed instruction, well done. For me it is too much, I would probably broke something along the way

, I found other DIY solution that doesn't require opening the door card, or soldering parts, have a look at this video, I think it is a good solution.

Roguedevelopmente90 · 11-17-2018, 12:02 AM

nice write up

ryan stewart · 03-10-2019, 05:07 PM

Thanks for posting this. With a guide it's like a 30 minute job. I did the handles and replace the cupholders and that replaced all of the worn soft-touch plastic. Car looks so much nicer now, nobody guesses it's a decade old.

Now if only doing the driver's door was so easy.

RPC · 03-10-2019, 06:22 PM

Excellent write up.

I did this recently and didn't have the tools or patience for melting the tabs - so used lock nuts from Lowe's (similar to these guys). The nuts dug into the plastic tabs and have proven to be secure so far. Worst case, I'll revisit and actually melt the tabs.

whyzee125 · 03-21-2019, 03:16 PM

Nice DIY; it will help a lot of people out! I did the same thing except instead of melting the prongs, I just used epoxy and let it dry overnight. Worked just fine.

Aus335iguy · 06-01-2019, 05:42 PM

The replacement handle i bought on eBay had screws and washers.
The e90 handle fits my e92. The e92 trim piece doesnt fit the e90 handle. Bought e90 trim to match and it all fits.

Hodgepodge · 06-30-2019, 04:56 PM

Hi, I had to replace the passenger side handle and used a woodburning soldering iron so I didn't destroy my good electronics iron. Woodburning irons have interchangable tips. Some have a quill tip and some have a flat plug tip. Here is one I would suggest. Well worth it. https://www.amazon.com/Weller-WSB25W...ateway&sr=8-12

hurry143 · 09-09-2019, 11:13 PM

I ordered my replacement trim cover + handle from Amazon: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
The handle came with screws as well and did not require any melting of plastic

xcrungordon328 · 11-11-2019, 08:42 AM

I purchased the inner/outter door handle for my 2011 328i with the black interior listed below. I can say that these are very good quality & easy to install. They came with everything needed.

I didn't use a torch, I simply just used a drill bit (I don't recall the size but I eyeballed it), to get the stud out of the OEM door handle.

Outter:https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

Inner:https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

Yoksel · 09-24-2024, 12:50 PM

The problem with sticky handles is really nasty, but trying this DIY was too much for me. I then looked at the other option up the thread with leather covering and it looked cool, but apparently is only available from the UK.

I then found these covers from Amazon and they look reasonable, cost very little and are easy to install. Worked well for me.
https://www.amazon.com/gp/product/B0...0?ie=UTF8&th=1

07-07-2015, 02:39 AM	#1
macmaverickk Enlisted Member 19 Rep 34 Posts Drives: 2013 F30 335i Join Date: Jan 2011 Location: Texas iTrader: (0) Garage List 2019 BMW 540xi [0.00]	BMW E90 Door Strap (Interior Door Handle) Replacement This is a rather simple DIY for a pretty common "sticky handle" problem with those of us in warmer climates. There are a couple ways of securing your new handle to the panel (besides having a dealership do it)... this is my way which worked out very well and I'm obviously taking no responsibility for people ruining their handles or burning their houses down. With that being said, let's jump into it! Items needed (In order of appearance): 1) 2 hours of free time (Which is more than you'll need) 2) Prying tools (For door panel) 3) Torx 20 Wrench (Also for door panel) 4) Diagonal cutting pliers (aka Dykes) 5) Dremel Tool (OPTIONAL... just makes things a bit easier) 6) A second person (Someone stronger than you OR someone you trust with the next item on the list) 7) Torch (Yeah, it gets that extreme) 8) Any kind of metal rod (Vague, I know... It's for the step where we're melting down part of the handle and reshaping the plastic... I used a butt-end of a ratchet... the butt-end of a chisel could work well also) 9) New Handle (it's comprised of two parts... No more than $30 total... no nuts or bolts to worry about either) STEP 1: Take off the door panel. I'll let YouTube take care of this step for me. THIS VIDEO is good. Obviously stop watching once the door panel is fully removed and speakers are disconnected (At minute 3:55) STEP 2: From the back of the panel, you can start working away at the melted plastic of the undesired handle: I found that using a Dremel tool with a hollowing tip made it easier for my dykes to hold onto and rip the plastic apart. STEP 3: Once most of the overlapping plastic is cleared, you should be able to just pull the handle straight out. May require some wiggling and forceful pulling (Keep your mind out of the gutter!) Out with the old, in with the new (Yes, I accidentally broke the old handle when taking it apart) STEP 4a: Alright, flip the puppy back over and you're going to want to get this up on a counter (needs to be well ventilated area like a garage). Also get something to support the other side of the handle, as there will be a lot of force coming down on it soon. See the plastic "prongs" from the new handle sticking out? Yeah, get your metal rod, torch, and assistant nearby... This is where it gets fun. STEP 4b: Get your torch on a very low setting and hold it between 1-3 inches away from your first plastic-pronged victim. It also helps to concentrate the flame on the shaft of the plastic prong too (Not pictured). After about 5-10 seconds of melting, have another set of hands forcefully crush the prong straight down with the "metal rod". You'll have to cycle between heating and pressing around 3-5 times per plastic prong. Once it is mostly crushed, start to s p r e a d the plastic around to give it a good base. Check the handle to see if there's any wiggle room... cause there shouldn't be (Remember, this piece is pulling the WHOLE door by itself. IMPORTANT NOTE: Do NOT directly heat your metal rod and use that to crush a cold plastic prong. Not only will the rod quickly get way too hot to handle, BUT the plastic will actually STICK to the rod, which the opposite effect of what we want. Do not worry about catching the panel on fire when warming the prongs, it's not at flammable as it looks. But obviously exercise caution and minimize flames. STEP 5: Put the panel back on the the reverse order that you took it off! Put the lock switch thing in at the top (no idea what you call it) first, and I started with the prongs at the top of the door, and then just hit the door all around the trim until all the snaps stopped. Screw in the Torx 20 screws, then snap on the second piece of the handle, and finally snap the trim into place! That wasn't so bad! If anyone else has used a different method of securing their door handle to the panel, definitely share your experience!! Last edited by macmaverickk; 07-08-2015 at 06:32 PM..
	Appreciate 3 ssdara65.00 whyzee1251980.00 Tweet Quote

07-11-2015, 09:26 AM	#2
BeastMode335i Maximus Decimus Meridius 1168 Rep 4,648 Posts Drives: F30 335i Join Date: Apr 2014 Location: Down South iTrader: (2)	Nice, thanks for the DIY.. I don't have these handles but I'm sure many will appreciate your tips.. __________________ F30 335i Melbourne Red Metallic M-Sport Package
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07-27-2016, 08:54 PM	#3
mrmcheung New Member 0 Rep 6 Posts Drives: 2007 TiAg 328xi Join Date: Jul 2015 Location: New Jersey iTrader: (0)	Thank you so much for this detailed DIY! Going to give it a shot as soon as I get the parts - do you have any recommendations as to where to find them according to your price range? I don't see any inner door pulls for less than $39.99
	Appreciate 0 Quote

08-05-2016, 05:08 PM	#5
opjose Major 244 Rep 1,371 Posts Drives: 335xi Join Date: May 2016 Location: Md iTrader: (0)	Out of curiosity: Could you have cut the new handle's plastic inserts flush from the back, then threaded a bolt and washer to both hold it in place and make it removable in the future? Were there any obstructions preventing someone from doing so? Thanks.
	Appreciate 0 Quote

08-13-2016, 01:15 PM	#6
marvel.marv New Member 2 Rep 11 Posts Drives: '17 G31 540ix, '16 F36 420i Join Date: Dec 2015 Location: Poland iTrader: (0)	Hey! It's much better to use a soldering iron just like this: Just heat it up and push it into the prong. You can cut 1/4 inch from the top of the iron if you wanna be extra careful to not go to the other side. __________________
	Appreciate 0 Quote

11-06-2016, 12:36 PM	#7
cdgatti Colonel 260 Rep 2,547 Posts Drives: e90 328i Join Date: May 2011 Location: KY iTrader: (4)	wonder if an electric heat gun could be used for this instead of the torch?? Would it be hot enough to melt the plastic? BTW this sure seems like a dumb design by BMW not making these just bolt in and out. __________________ OEM Black grill and Blackline tails - LCI halogens with Lux V2 coded as DRL - 3M Crystalline - BMS PBX - OEM Euro Airbox with K&N - Hardwired CTEK - Bilstein B6 w/OEM springs and SP perches - Conti DWS06 - HiFi-Helix DSP - JLAudio HD/XD-Morel - CD changer trim - AE optical out
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11-02-2018, 05:22 AM	#9
kugarek New Member 2 Rep 10 Posts Drives: E91 2007 Join Date: May 2018 Location: Grays iTrader: (0)	Other DIY solution Wow this is a very detailed instruction, well done. For me it is too much, I would probably broke something along the way , I found other DIY solution that doesn't require opening the door card, or soldering parts, have a look at this video, I think it is a good solution.
	Appreciate 1 Phil325i634.50 Quote

11-17-2018, 12:02 AM	#10
Roguedevelopmente90 Registered 0 Rep 2 Posts Drives: Bmw e90 335 Join Date: Nov 2018 Location: Indianapolis iTrader: (0)	nice write up
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03-10-2019, 05:07 PM	#11
ryan stewart Major 2241 Rep 1,347 Posts Drives: 2008 328it Join Date: Aug 2012 Location: Atlanta, GA iTrader: (0)	Thanks for posting this. With a guide it's like a 30 minute job. I did the handles and replace the cupholders and that replaced all of the worn soft-touch plastic. Car looks so much nicer now, nobody guesses it's a decade old. Now if only doing the driver's door was so easy.
	Appreciate 0 Quote

03-10-2019, 06:22 PM	#12
RPC Enlisted Member 15 Rep 38 Posts Drives: 2011 e90 M3 Join Date: Feb 2019 Location: Davidson, NC iTrader: (0)	Excellent write up. I did this recently and didn't have the tools or patience for melting the tabs - so used lock nuts from Lowe's (similar to these guys). The nuts dug into the plastic tabs and have proven to be secure so far. Worst case, I'll revisit and actually melt the tabs.
	Appreciate 0 Quote

03-21-2019, 03:16 PM	#13
whyzee125 Brigadier General 1980 Rep 4,004 Posts Drives: Dinan stage 2 335i Join Date: Jul 2014 Location: Chattanooga Tn iTrader: (0)	Nice DIY; it will help a lot of people out! I did the same thing except instead of melting the prongs, I just used epoxy and let it dry overnight. Worked just fine.
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06-01-2019, 05:42 PM	#14
Aus335iguy Colonel 656 Rep 2,139 Posts Drives: 2009 e92 335i MSport DCT Join Date: Jul 2015 Location: Sydney Aus iTrader: (0) Garage List 2009 BMW 335i [10.00]	The replacement handle i bought on eBay had screws and washers. The e90 handle fits my e92. The e92 trim piece doesnt fit the e90 handle. Bought e90 trim to match and it all fits. __________________ When you doppelkaplung you doppel your fun. Last edited by Aus335iguy; 06-01-2019 at 07:39 PM..
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06-30-2019, 04:56 PM	#15
Hodgepodge Dude with a lot of BMWs 2 Rep 27 Posts Drives: E93(2),E70,E61,2002(2),++ Join Date: Oct 2011 Location: Western PA iTrader: (0) Garage List 2009 BMW 328i E91 [0.00] 1991 BMW M5 [9.75] 1974 BMW 2002 [0.00] 2002 BMW M5 [0.00] 1988 BMW M5 [10.00] 1988 BMW M5 [9.75] 1975 BMW 2002 [0.00] 2012 BMW X5 [0.00] 2008 BMW 328i Conve ... [0.00] 2008 535i Touring [0.00] 2009 335i Convertible [0.00]	Hi, I had to replace the passenger side handle and used a woodburning soldering iron so I didn't destroy my good electronics iron. Woodburning irons have interchangable tips. Some have a quill tip and some have a flat plug tip. Here is one I would suggest. Well worth it. https://www.amazon.com/Weller-WSB25W...ateway&sr=8-12 __________________ Current: E70, (2)E93, E91, E61 (2)2002, (2)E28M5, E34M5, E39M5 (11 BMWs total) (2) Alfa spiders, (2) Dodge trucks, Prior: 18 other BMWs
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09-09-2019, 11:13 PM	#16
hurry143 Registered 0 Rep 1 Posts Drives: 2009 BMW 335i Join Date: Sep 2019 Location: Sunnyvale iTrader: (0)	I ordered my replacement trim cover + handle from Amazon: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1 The handle came with screws as well and did not require any melting of plastic
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11-11-2019, 08:42 AM	#17
xcrungordon328 Registered 0 Rep 2 Posts Drives: 2011 BMW 328i (xDrive) Join Date: Jan 2018 Location: Valley Stream, New York iTrader: (0)	2011 328i Door Handle Replacement I purchased the inner/outter door handle for my 2011 328i with the black interior listed below. I can say that these are very good quality & easy to install. They came with everything needed. I didn't use a torch, I simply just used a drill bit (I don't recall the size but I eyeballed it), to get the stud out of the OEM door handle. Outter:https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1 Inner:https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
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09-24-2024, 12:50 PM	#18
Yoksel Enlisted Member 13 Rep 42 Posts Drives: 2010 328i xDrive, 2021 X3 Join Date: Jul 2014 Location: Sarasota, FL iTrader: (0)	The problem with sticky handles is really nasty, but trying this DIY was too much for me. I then looked at the other option up the thread with leather covering and it looked cool, but apparently is only available from the UK. I then found these covers from Amazon and they look reasonable, cost very little and are easy to install. Worked well for me. https://www.amazon.com/gp/product/B0...0?ie=UTF8&th=1
	Appreciate 0 Quote