There wasn't any guide with pics online before, so .... nature abhors a vacuum.
A common problem with 95+ 960 models (and 1997-8 S90 / V90 models) is the failure of the hysteresis spring within the internal door handles. The spring breaks, often ejecting a small piece of broken spring which looks like a rod, out from the door handle. When this happens, the door handle doesn't return to its seat.
These door handles are different from pre-95 960s, and from 940s / 700 series.
While complete internal door latch units [1] aren't available any more from Mother Volvo, GCP does however carry replacement hysteresis springs [5]. They are -
p/n 9126002-6 for left-side door handlesp/n 9126003-4 for right-side door handles
Tools needed:
T25 Torx tool and driverpair of pliers2mm drift (nail, old pop rivet can also work)small flat blade screwdriver
Picture for reference:
The repair process is as follows:
Unclip the frame [7] from the door lock. Remove the cover plate near the door handle to access two T25 Torx screws and remove. Gently remove the power window switch and support panel, and unplug the switch. From the bottom of the door card, remove the 3 white plastic attachment clips - note that the clip closest to the 'A' pillar is slightly more difficult to access than the other 2 (one in the middle; one at the 'B' pillar end).Lever the door card away from the door about 2cm, then lift the door card up and out, remembering how the door marker light is still insitu; unplug this light and lift the door card free. You're then faced with something that looks like this (LH side shown).
(7) Using your drift (or drift substitute) gently tap down the pin indicated by the yellow arrow in the picture below (this is [3] in the diagram above) and withdraw the pin.
(8) When you withdraw the pin, the lock button and door handle will then all be loose. Note how there is also a coil spring behind the locking latch.
(9) The photo below shows the broken hysteresis spring sitting inside the door handle. Remove and replace it.
(10) Installation is the reverse of the above process. Note that the long part of the spring is designed to sit in the little recessed area indicated by the circle in the picture below.
