Problem: loose stud on door handle, More problems Options

[bbrock]

Hoping to get some BTDT wisdom. I'm simply trying to remove the passenger side door handle and hit a major snag. The little M6 stud that attaches to the tab on the outer part of the handle is just spinning free so I can't get the self-locking nut off.

(IMG:http://www.914world.com/bbs2/uploads_offsite/cdn4.pelicanparts.com-20845-1499725820.1.JPG)

It isn't broken, it is still attached to the tab on the door handle, but loose inside. I've tried soaking the nut with PB Blaster, heating it with a propane torch, and trying to wedge a flat blade screw driver against the stud in an attempt to create more friction resisting the stud turning than needed to break the nut loose. There isn't a lot of room in there to work and I know from sad experience how easy it is to break the pot metal on these things. The only options I see now involve a drill and destroying the stud, or drilling in from the outer (tab) side to try to pin the stud enough to get the nut off. Either way, I need to make sure there is a path forward for a good repair. Even better would be the third option that you are going to tell me about (IMG:style_emoticons/default/smile.gif)

[arne]

If the stud is spinning, it has a problem and there's no reason to worry about damaging it. It will need to be replaced anyway, perhaps with an oversized stud. I believe that someone here on World can repair these handles.

[URY914]

I believe that someone here on World can repair these handles.

That would be me. (IMG:style_emoticons/default/biggrin.gif)

Cut off the stud/nut. Remove the handle. Drill the out stud. Replace the stud with a bolt or counter sink a screw.

If (or when) you break the mounting tab off when doing this, send it to me and I'll replace the tab.