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Discussion Starter · #1 · (Edited)
See a few people asking about to remove the door card on the Rover 400/45 and MG-ZS. I went out to check my window mechanism and thought I would do a guide to the removal of the front door card.

My car is 1996 Rover 414 with electric front windows. I assume this method is very similar if not the same for newer cars.


Tools Needed: Flat blade screwdriver and a Phillips screwdriver (magnetic one if possible)

Time: 30 minutes max...I did this in 10 minutes, but for first time round its quite awkward as I found.


The guide:

#1 Open the window fully (you will see why later) and start by unscrewing the screw on the door release handle:



#2 Slide the handle to the front of the car, thus unclipping it from its housing. You should see the rod going to it with a plastic clip. With the Phillips screw driver, push the BOTTOM of the clip..not the top... round so you unclip it from the rod. Do this carefully as these are buggers for snapping. You should now be able to remove this handle.





#3 Unscrew the two screws in the grab handle:



#4 Now just remove the small plastic screw from the top corner of the door card. It is a posi screw, but I found it easier just to pop it out with the flat blade.



#5 With a flat blade screw driver, carefully push it between the door card and the door and lever it towards you. The bottom is just popped on, so you should hear it "unpop" from the door. Once you have got it half off, you can then remove it with your hands.




#6 Finally unhook the lock pin from the door card.



#7 If your car has electric windows, you will see two wires clipped on to the door card

Alarm LED Wire [N.B Newer cars do not have the LED in the doors as they are on the Dashboard. I think it was just the first bubble shape 400's that had it]


Electric window switch wire


Unclip these to free the door card.

You may notice that my door hasn't got the plastic sheeting. I found this to be a pain and just removed it. I haven't seen anything untoward happen, i.e leaks, from removing it. So its up to you if you want to keep it on there or not.

Refitting.

This can be very tricky first time. But I found a trick/workaround to the problem.

#1 Remove the mirror backing


#2 Line the door card "front" end to the front of the car. (This is why its good to have the window open :) makes life easier)


#3a Line the door lock pin back up with the hole.

#3b then move the rest of the door card onto the rest of the door (don't worry if the pin falls out, you can rescue it once you got the door card back on) The pin should be lined up nicely like this


#4 Screw the grab handles two screws back in. (this is where the magnetic screw driver come in :) )

#5 Try to find the door release handles rod, once you found it, use a flat blade screw driver to lift it up and into the hole on the handle itself and then with the posi driver scew driver or your hands, rotate the clip and pop it back on the rod.


#6 Now give the bottom of the door card a couple of thumps to "pop" it back on the door.

#7 Now you should be able to clip the door release handle back on and screw that in.

#8 Going from the bottom up, put the mirror backing back on. This is a bit fiddly, but you should get enough play from moving the door card towards you a bit to get it on.


#9 Finally, put the plastic posi screw back into the corner of the door card.

Job Done :broon:
 

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Thread has been moved to the 'How Do I' section.

Great guide Gareth. Thank you for taking the photos and doing the write-up. It's little guides like this that help make the forum great. :D

Ian.
 

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Cheers!

Superb post! Cheers. Driver's door window of my ZS had stuck down. Using your guide I was able to get the card off without fear of breaking anything. A quick adjustment to the motor with a Black Country screwdriver and all was well. Thanks again. PS> I didn't notice any difference between your guide and what I was seeing on my 51 ZS.
 

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Superb post which helped me change my wing mirror!

A quick note for refitting the card if you have speakers at the top of the door (this is how I did it on my 2002 Rover 45 and 2002 MG ZS):

  • Reconnect the speakers using the plug, but don't clip it to the door yet;
  • Using the cable to hold the speaker unit, carefully hang it from the open window so it isn't in the way while you fit the door card;
  • Line up the door card (3a and 3b in the photos) but *don't* push it right into place; let it loosly hang on the door but leave enough room to refit the speakers;
  • Now put the speakers back into place
  • And follow the rest of Gareth1982's instructions ;-)
 

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little clip

Hi does anybody know how I can get my hands on one of those clips on the door handle rod that snap ever so easy, without it I can't open my door from inside. :'(
 

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1998 Rover 4.14 (1.6:))
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Merhaba Hello, what is the size of the car door speaker? I want to replace my 400 rover car with the door speaker, and can you help me with the speaker in the back trunk? Thank you in advance. :)
 
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