C - MK4 Rear Doors Handle Assembly

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C - MK4 Rear Doors Handle Assembly

How to assemble Rear Mk4 canopy handles

How to assemble Rear Mk4 canopy handles

1

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<p><strong>CQC:</strong></p><ul><li style="font-weight: bold;"><strong>Standard lock barrel</strong></li><li style="font-weight: bold;"><strong>Same internal mechanism as Trailcore</strong></li><li style="font-weight: bold;"><strong>Actuator as standard</strong></li><li style="font-weight: bold;"><strong>New housing and handle </strong></li></ul>

CQC:

Standard lock barrel
Same internal mechanism as Trailcore
Actuator as standard
New housing and handle

2

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Inspect all powder coated parts for any defects refer to PCQC02

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<p>For this process you will need to use the TC ALL/CPY REAR handle riveter on the TC handle assembly station.<br></p>

For this process you will need to use the TC ALL/CPY REAR handle riveter on the TC handle assembly station.

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<p>Find PRT-005197-01 and PRT-005323-01</p>

Find PRT-005197-01 and PRT-005323-01

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Connect both the parts by using the rivet press.

Ensure you connect them with PRT-005197-01 on top of the folded part of PRT-005323-01

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7

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PRT-005323-01 then gets connected to the other end of PRT-005199. Ensuring it is connected underneath.

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Connect using the rivet press

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PRT-005200 is then connected to the end of PRT-005199 using the rivet press.

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Connect using the rivet press

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<p>Example for reference </p>

Example for reference

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Slide PRT-005264 over PRT-005199 and the rivet into the center of PRT-005200.

NOTE: some of these holes on the lock mechanism is very tight. DO NOT DRILL simply use a hammer to get the rivet in place.

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Secure with the rivet press.

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Example as reference

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Connect the internal latch PRT-006074 to PRT-005200. Secure with the rivet press.

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Secure with the rivet press.

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<p><strong><em>When tightening these next lot of threads ensure you are using BLUE MEDIUM STRENGTH loctite.</em></strong><br></p>

When tightening these next lot of threads ensure you are using BLUE MEDIUM STRENGTH loctite.

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Standard barrel goes through the hole on PRT-011225.

19

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Placing PRT-006512-01over the back of the barrel and secure with a M20 half nut.

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Place the sponge foam on the bottom of PRT-011225.

This is to stop the handle from hitting the back plate and making noise/scuffing etc

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Slide a foam washer on to ASM-006815 (standard shaft)

Slide the shaft through PRT-011225. Sliding a rubber washer then PRT-008332 then another rubber washer before sliding through the other side of PRT-011225.

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Secure the shaft in place with a washer and a Socket head bolt.

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<p>Reference photo.<br></p>

Reference photo.

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<p>slide the spring on to the end of the shaft and hook around the shaft.<br></p>

slide the spring on to the end of the shaft and hook around the shaft.

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Place PRT-006505 (crush washer) on the lock barrel.

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<p>Place PRT-005197-01 on to the barrel and arrange the lock mechanism like the image.<br></p>

Place PRT-005197-01 on to the barrel and arrange the lock mechanism like the image.

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<p>Place PRT-005198-01 on the lock barrel and through the slit in PRT-005197-01.<br></p>

Place PRT-005198-01 on the lock barrel and through the slit in PRT-005197-01.

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Apply Loctite on the barrel thread and Flange nut.

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<p>Tighten until flush </p>

Tighten until flush

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<p>On the side of the assembly there are two holes that need to line up with PRT-011225 and PRT-005264.</p><p>Secure with rivets.<br></p>

On the side of the assembly there are two holes that need to line up with PRT-011225 and PRT-005264.

Secure with rivets.

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<p>Hook the spring from PRT-005197-01 to PRT-005200<br></p>

Hook the spring from PRT-005197-01 to PRT-005200

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<p>Hook the spring from PRT-006512-01 to PRT-005197-01<br></p>

Hook the spring from PRT-006512-01 to PRT-005197-01

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<p>Rivet the CLK bracket (PRT-005780) to the side of PRT-011225.<br></p>

Rivet the CLK bracket (PRT-005780) to the side of PRT-011225.

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Place the actuator bracket on to the actuator and secure with screws

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<p>Line the actuator bracket up with the CLK bracket and secure with bolts.<br></p>

Line the actuator bracket up with the CLK bracket and secure with bolts.

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Spin the end of the actuator, hook the rod into the hole and clip into the pivot.

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<p>Reference photo of completed MK4 Rear Door Handle Assembly.<br></p>

Reference photo of completed MK4 Rear Door Handle Assembly.