D.I.Y Sedan trunk release lever.

[Danny-G]

I've noticed many first gen. sedans have broken trunk release levers, not sure if its a problem for second gen. Heres how to get a new one from a wagon.

Items needed.
-Wagon gas flap release lever.
-Smaller round file.
-Saw or something to cut the plastic.
-Average sized flat file.
-Paint that closely matches you're interior color. (note, the paint isn't really required.)
-Something to hold the wagon gas flap lever when you cut it.


Step 1.
Get all the required parts.
https://sl-i.net/FORUM/images/imported/2011/07/100_1769-1.jpg

Step 2.
Put the lever in a vice as seen below.
https://sl-i.net/FORUM/images/imported/2011/07/100_1771-1.jpg

Step 3.
Cut the lever as seen below, make sure to end the cut before it gets the side with the opening for the release arm thingy.
https://sl-i.net/FORUM/images/imported/2011/07/100_1772-1.jpg
https://sl-i.net/FORUM/images/imported/2011/07/100_1773-1.jpg

Step 4.
Re-position the lever in the vice as seen below.
https://sl-i.net/FORUM/images/imported/2011/07/100_1775-1.jpg

Step 5.
Cut the lever again as seen below. Expect the now trunk release lever to fall after finishing this cut.
https://sl-i.net/FORUM/images/imported/2011/07/100_1776-1.jpg
https://sl-i.net/FORUM/images/imported/2011/07/100_1779-1.jpg

Step 6.
Take the flat file and smooth the longer edge out along with the shorter edge. Use the round file in the corner to retain a factory look.
https://sl-i.net/FORUM/images/imported/2011/07/100_1781-1.jpg

Step 7.
If you're not painting it, go take the old broken trunk release lever off and put this one on and enjoy you're "brand new" trunk release lever!
https://sl-i.net/FORUM/images/imported/2011/07/100_1782-1.jpg

Step 8.
If you're painting it, sand it lightly with the flat file, hang it or put it on a table to paint it, then spray the paint in light coats untill you have the whole piece coated evenly. Then re-coat if you feel the need to and, also if you feel the need to, clear coat it. I don't have pictures of the painting process but I think you can figure that out.


Step 9.
After letting you're painted trunk release lever dry over night, go to you're car, remove the broken one and after making sure the paint is dry install the "brand new" trunk release lever and enjoy it!
https://sl-i.net/FORUM/images/imported/2011/07/100_1795-1.jpg

If anyone has any question feel free to ask.
Side note, this is my first D.I.Y write up so I know its probably not perfect. Hope this helps many sedan owners like it did me once I figured it out.

[chuckthefuk]

Mint..

Just as common on Gen 2 BD/BK/BG.

[httrdd]

Prob easier to just get another one at a junk yard, since you have to get this one from there too. I appreciate the effort though.

[Danny-G]

If more sedans were in the junk yard then I would. The only sedan I found at a junk yard was a '91 and the lever was broken.