Thanks for this video, I found it as I’ve had a problem with the locking mechanism that I wanted to try to sort out. Removed the door card as per your video and amazingly I discovered that exactly the same part of the door as yours had sheared, which of course is where the manual locking latch is mounted. Fixed it with a bit of thin aluminium plate and a couple of tea screws. Not as elegant a fix as yours but did the trick.
Nice job. Just got some doors on mine, the doors are good enough but the door card and internals left a lot to be desired. I ended up reusing some of the internals off the old door, in the new door! LOL
My door (1999 TD5) did exactly the same, but actually ended up splitting in two pieces and coming off completely! I welded it back together and hope it will hold for a few years at least. By the way, on my winder, the handle is held on with a U clip that needs a trim tool to remove it. Then the winder pulls off the splined shaft, no screws.
It’s such a weird fault isn’t it! I was wondering if someone had tried to break in at some point but couldn’t see how they could make that kind of damage!
@@TheOrangeDefender I think it's just a stress point that's particularly weak. When you look at the material in that top section, there's not a lot of meat to it. The section the window regulator is on is described as a reinforcement panel, so they knew it was rubbish! Because mine broke either side of the latch, it meant that the plastic locking tab flapped about and then the door card flapped in the breeze too. I was forced to do something about it when I discovered that the door button on the outside was four feet away from my car. It was that cold snap a few weeks back, guess it just gave out. Fitting the new door handle was more of a pfaff than it should have been, a stupid anti-rattle clip snapped and meant you couldn't just reassemble it without a new one. Just put it all back together today, I predict it will hold out until the weekend! Hey, we'd be bored if they just worked...
@@TheOrangeDefender thanks very much. Just bought my 1st defender, a 90 from 1989 with a 200tdi and already I've had to watch 3 of your videos..... and I only have it since sunday morning last. 😀
Thanks for this video, I found it as I’ve had a problem with the locking mechanism that I wanted to try to sort out. Removed the door card as per your video and amazingly I discovered that exactly the same part of the door as yours had sheared, which of course is where the manual locking latch is mounted. Fixed it with a bit of thin aluminium plate and a couple of tea screws. Not as elegant a fix as yours but did the trick.
Nice job.
Just got some doors on mine, the doors are good enough but the door card and internals left a lot to be desired. I ended up reusing some of the internals off the old door, in the new door! LOL
Good description, thanks.
My door (1999 TD5) did exactly the same, but actually ended up splitting in two pieces and coming off completely! I welded it back together and hope it will hold for a few years at least. By the way, on my winder, the handle is held on with a U clip that needs a trim tool to remove it. Then the winder pulls off the splined shaft, no screws.
It’s such a weird fault isn’t it! I was wondering if someone had tried to break in at some point but couldn’t see how they could make that kind of damage!
@@TheOrangeDefender I think it's just a stress point that's particularly weak. When you look at the material in that top section, there's not a lot of meat to it. The section the window regulator is on is described as a reinforcement panel, so they knew it was rubbish! Because mine broke either side of the latch, it meant that the plastic locking tab flapped about and then the door card flapped in the breeze too. I was forced to do something about it when I discovered that the door button on the outside was four feet away from my car. It was that cold snap a few weeks back, guess it just gave out. Fitting the new door handle was more of a pfaff than it should have been, a stupid anti-rattle clip snapped and meant you couldn't just reassemble it without a new one. Just put it all back together today, I predict it will hold out until the weekend! Hey, we'd be bored if they just worked...
Just a heads up sometimes the windows handles are held on with a metal clip that holds the handle onto the shaft it’s a massive pain
I've seen the clip you're talking about and yes "a massive pain" is putting it nicely!
The Orange Defender yea tell me about it, just renovating a td5 110 csw and trying to save up for a full set of galv doors
My door split the same. Stripped everything off it so welding sparks did not mark the glass and had it welded up, cost £20
Yes, I've just done this again and welded it this time, i think the passenger side is on the way out too!
What's the name of the adhesive?
It’s Beko allcon 10 construction adhesive. Still good after 6 months so highly recommend!
@@TheOrangeDefender thanks very much. Just bought my 1st defender, a 90 from 1989 with a 200tdi and already I've had to watch 3 of your videos..... and I only have it since sunday morning last. 😀
Glad you’re enjoying it already. It can be a battle maintaining them sometimes but it’s well worth it!