Fiat 500 Broken Door Handle Hinge Fix So our Fiat 500 door handle hinged broke the other day, seems another ‘feature’ for the Fiat 500, and I thought I would post the steps to replacing the Fiats...

[UK Sentinel]

So our Fiat 500 door handle hinged broke the other day, seems another ‘feature’ for the Fiat 500, and I thought I would post the steps to replacing the Fiats drivers side door handle hinge.

 

So after taking the Fiats door handle apart, seems the door handle hinge has corroded in position and hence the break.

 

Steps to Replace Fiat 500 Door Handle Hinge:

So ordered a replacement door hinge from AMAZON, lots to choose from and cost around £10.

 

Gaining access to the Door handle hinge involves removing the Drivers side door card (internal door cover) which entails removing the internal door handle cover with a plastic door card removal tool. This reveals a single M5 hex screw which should be removed.

 

Then remove the Arm rest cover to expose a further 2x M5 hex screws, then remove these screws also.

 

Then at the edge of the door, remove the single TX30 Torx screw which helps free the door handle from the door.

 

Now the door card can be removed which is held in by a series of pop fasteners.

 

Fiat 500 Door with Door card removed, I deliberately left the internal Door handle cable attached to Door Card as I could see no reason to remove it, but I did pop out the electronic side mirrors positioning switch.

 

To remove the bolt holding the Fiat 500 door handle hinge, a small slot needs to be cut into the door lining to gain access to the M6 (10mm flathead) nut which needs to be removed.

 

Then slide the Door handle to the Right and then from underneath rotate the door handle upwards which creates just enough room to then gain access to door hinge screw attached to the door handle itself.

 

Then with a Stub Cross Head Screwdriver, gentle removed single screw that holds the hinge to the door handle.

 

Once the Door hinge has been removed, just reverse the process for re-assemble, I did place some masking tape around the door hinge area to stop any potential scratching of paintwork.

 

 

Door handle hinge replaced and ready for another few years of neglect.

.

In a completely sane world, madness is the only freedom (J.G.Ballard).

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[UK Sentinel]

Picture below of new Fiat 500 replacement door hinge for reference and the hinge pivot area was smothered in silicon grease before re-assembly.

Note: I did not use new screw and grommet as original screw and grommet seemed in good condition.

In a completely sane world, madness is the only freedom (J.G.Ballard).

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