I have a 96 XJS that developed a loose part inside the drivers door. It sounds like a connecting rod that has come loose on one end and rattles when you close the door. What kind of trouble am I facing getting the door open to repair it? Taking off the door card does not look difficult but can I access the locking mechanism without tearing the whole door apart? Any help will be appreciated. Thanks.

 

Door card is rather straightforward. With that off, you should be able to access everything you need. Space is tight, and most areas require the window in the up position to reach. Not much to take apart once the card is off.

 

There are door lock rods in there that run thru plastic guides. They just snap in. sounds like one of those just popped out. Should be very simple fix.
Suggest while you are in there use some White Grease on the rods, window runners, window motor.

 

Some issues you will encounter are:
There is a Posi-Drive screw under the arm rest ferrule that needs to be removed.
Sliding it back far enough to put a screw driver on it can damage the arm rest leather.
I replaced all mine with hex head screws so I can get them off/on just moving the ferrule 1/4".
Under the door cards are plastic/foam vapor barriers which are difficult to remove without tearing.
They are attached with Dum-Dum adhesive, which has the consistency of bubble gum.
You can't get it off either surface completely and it will transfer permanently to anything it touches.
If you can fix your problem without messing with the vapor barrier, leave it alone.

 

+1 for equiprx comments!

That armrest end-cover is a real nuisance. Go very easy on that, manipulating it back the minimum amount to get the screw.

Also, the press fixing clips all around teh door card are fragile (whilst being difficult to release!) and are attached into the door card through slotted holes. With the propensity for the fibreboard doorcard to age and rot if it gets moist, you need to lever the clips out of their holes carefully. Use a proper plastic trim removal tool.

After that, as you probably know, you have to slightly lift and lean the doorcard to extract it and remember that you'll have the speaker wires still attached.

Good luck

Paul

 

Thanks for the replies. I don't know when I'll get to fixing it but wanted to know what I was up against. Looks like if I'm careful it is doable.