Thread: Land Rover 90/110 Front Lift Up door handle assemblies (Santana) – Repair

My 1985 110 County experienced both front door handle return spring breaking within months of each other, last year. Obviously a spring fatigue issue. Upon lengthy research in sourcing replacement door handles, I only managed to source one similar Army configuration non locking unit ($200) as all available spares had been exhausted. However, although different and without an external key lock capability, the Army configuration assembly did give me the opportunity to remove/replace the driver assembly and research options. There are spring manufacturers in Australia who will reverse engineer wire tension springs to any OEM shape for approximately $10 each. Upon disassembly, other parts of the latch assembly look capable of manufacture or repair using minimal fitting skills. Repairs to the lift handle which was a welded assembly could be a challenge. The engaging claw is a forged or cast item.

Repair process.

1. - Remove door handle assembly from door

2. - Remove two rivets (pull through type) holding internal remote and button mechanism to latch assembly.

3. - Carefully drill and punch out seven solid rivets holding backing plate. Slide a small 4-5 mm dia common flat screw driver into the internal remote lever axel /pivot hole slot as the rear case is lifted off – this maintains the location of this remote lever & spring position. The back plate will lift off the remote lever pin and the main claw axel pins by lifting the FWD edge first. (Note - There are no hidden spot welds or tightly pressed components as I feared.) Once again take note of the remote actuation lever return spring position / screw driver should now be inserted fully to hold this position. This spring can be refitted if the position is lost by either using the opposite latch disassembly as a guide or studying how it operates.

4. - Lift handle return spring (normally broken) can now be removed. I sent this to Specific Springs, Blacktown (or equivalent spring manufacturer) where they manufactured three right hand and three opposite left hand springs for $40. It is possible to replace any of the internal springs as needed by reverse manufacture of the broken spring.

5. - I removed the Key Lock mechanism and cleaned the internals and added alight coat of molybdenum grease to the bore. One of the two each ball bearings was missing and was replaced with a 3/16 bicycle axel ball of a similar size. I then reassembled the key lock mechanism and tightened the small bolt and actioned lock tab. The latch backing plate can been removed or fitted with key lock barrel fitted.

6. - The external Lift handle is loose when the spring is broken or removed. This allows enough movement to clean and relube the pivot point bearing. (I used molybdenum grease and a small brush) New manufactured return spring can now be clipped into place to securely hold the lift lever. The spring tension holds the lift handle bearing in place.

7. – Refit the rear backing plate using the small common flat screw driver to align the internal remote lever and spring into position on its axel slot. The main locking claw axel will engage as the leading edge of the backing plate is closed into original position.

8.- The latch backing plate can now be temporally fastened using alignment pins and a couple Vice-Grips allowing the mechanism checked for operation.

9. - Solid rivets can be replaced or holes drilled out to suit 4mm x 3.2mm (1/8” grip) size steel pop rivets and actioned from the outside while maintaining the assembly with Vice grips and bench vice. The rivet under the lift handle can be difficult for access and was installed by removing the mandrel from the pop rivet and action using punch or ball peen hammer.

10. - Internal remote and lock button mechanism can now be seated firmly into the original position with the remote lever checked for position and operation before secured by two 4mm x 3.2mm (grip pop rivets. Re-check for ease of operation.

11. – Refitted latch assembly into the door in reverse removal procedure. (Note parts repair cost was around $12 each latch assembly and a few hours labour for careful beginners. A skilled person could complete this process in 30 mins).

I have attached a photo of the lift handle assemblies.