T5 Sliding Door Jam Repair
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Description
On our T5 Caravelle, the sliding door could no longer be opened from the outside. But with a little “pumping” on the inner lever, it still worked.
After some research, I found the following post:
The post nicely explains that the cause is probably the stretched Bowden cable. And since the lever on the outside is mechanically limited, there isn't enough “hub” reaching the locking mechanism.
I was looking for a solution where I don't have to remove the entire main lock, but only adjust the locking mechanism. However, I didn't want to bend the lever, which cannot be removed. Another solution was needed.
Here's my approach:
Due to the suspected stretching of the Bowden cable, the lever needs a little more pre-tension to function correctly.
To achieve this, I developed an adapter that relocates the position of the Bowden cable's attachment point.
The adapter (blue-grey here) is placed onto the lever (red here) and screwed on there.
The small pins serve to protect against twisting
Installed, it looks like this:
The white holder is removed from the original 5mm hole and reinserted into the printed part below.
Warning
This is still a test case.
The adapter is printed from PETG with 100% infill. Let's see if it holds up. If plastic is not sturdy enough, I will see if I can have it made from metal.
The adapter is printed from PETG with 100% infill.
Sizes
There are four different sizes 7, 8, 9, 10. You need to try out which size provides enough “hub” for the door to always open reliably. I am currently using size 8.
Assembly
I cannot explain here how to remove the sliding door trim or how to disassemble the locking mechanism.
For those for whom this is not a problem, you can proceed here.
You will need
1 x printed adapter plate
1 x M4 countersunk screw with internal hexagon
1 x M4 nut
some threadlocker (aka. Loctite)
After removing the locking mechanism, you have to unhook the Bowden cable
and carefully remove the white holder
Then you insert the white holder into the adapter plate.
Then you put this onto the lever arm
and screw it on tightly there. (First without threadlocker)
Then you just need to hook in the Bowden cable
Then, with the locking mechanism in one hand, you can operate the exterior door handle with the other and check if everything works.
Finally, apply some threadlocker to the screw and tighten it well.
Boost Me (for free)
If you like this model, I would be very happy about a boost.
License
You shall not share, sub-license, sell, rent, host, transfer, or distribute in any way the digital or 3D printed versions of this object, nor any other derivative work of this object in its digital or physical format (including - but not limited to - remixes of this object, and hosting on other digital platforms). The objects may not be used without permission in any way whatsoever in which you charge money, or collect fees.
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