Door Panel/Handle

2005 Jeep Door Handle Panel problems with breaking

Houston… I mean Detroit, We have a problem. The 2005 Jeep Grand Cherokees have a problem with the door panel/handles cracking, breaking and literally disintegrating. Here I’m going to show you what I did with mine. You may take the idea and run with it. If you come up with something better, please share. Obviously the easiest thing to do, would be to just buy new door panels. Only problem is they can cost several hundred dollars each. Multiply that times 4, and well…
So until Jeep does a recall, I had to come up with another idea. I tried to find some on ebay, but no luck there either.

First remove the door panel. I won’t try & reinvent the wheel so here is a good link. Door Panel Removal I do have video I made, but haven’t had time to upload it yet. Sometimes it can be a little difficult to put the panel back on, but just remember to get the manual lock rod in the hole and bend out the top just a little to get it started in the lip and you should be fine.

Two cheap ways I repaired mine. The ones that were totally gone, I made a U shaped bracket out of metal, drilled a hole for the pivot pin and screwed it to the door and reinstalled the pull handle. The metal I used are straps  I found at Lowes/Home Depot used to secure lumber together. (see pic below) Overall, doesn’t look that pretty, but hey, in case of a wreck, my family will be able to open the dang door. I’m still working on a backdrop/filler to make it look better. Just haven’t had the time to create anything.

The ones that were just starting to crack, I removed the door panel and put Bondo all over the back side to reinforce it before it does fall apart.

Number 1   –  U -Bracket

Notice that I hacksawed one edge about a 1/4 in and bent it over to use as a stop for the round rubber stop on the handle. It just keeps the handle from popping out too far. If you have to go this route, take a look at the videos page where he is drilling out the plastic rivets to remove the excess.

Click on the Photo for Larger Image

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Number 2  -  Bondo

I mix up the Bondo on old corrugated election signs (or you can use cardboard) and use craft sticks to mix. Do it in a couple of sections at a time, because it drys fast. So far, it’s worked great. I saw some on the internet that used fiberglass/resin, but I have never worked with it. Seemed more time consuming. I did try Durhams Putty on one door. But after it dried the excess I had left over in a cup seemed brittle. So far it’s working fine on the door. Maybe because I put it on thick. But I just decided to go with the Bondo, because I’ve used it before and I know it will hold.

Click on the Photo for Larger Image

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Number 3  -  Handmade Fiberglass

The guy in the video drilling out the rivets, apparently hand makes a replacement out of fiberglass. If yours is broken bad and you want it to look better, then this is probably a better choice. Only problem is, I think he is located in Italy?  These posts give a little more detail

http://townhall-talk.edmunds.com/WebX?14@@.f16a9e4/20

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Number 4  -  Junk  Yard Dog…

From another forum @

http://www.jeepsunlimited.com/forums/showthread.php?p=4660764

Not sure how long they would last since they are from the same model??

tig488 I replaced my interior door handle panels that broke myself. i found a junkyard with door panels for sale, paid 25 bucks for each, tore them apart, painted the piece to match mine, and mounted it on my door using plastic bond from lowes. worked great and looks stock, nobody could even tell. fixed front and rear for 50 bucks and it took less than an hour for both. jeep can eat a fat one.



Another site with Door Panel Info… DenLors Tools

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