Door Panel Popper - Any Suggestions?

[Deep Blue]

Removing front inside door panel (door card). All okay so far removing four screws (two hidden behind pop-off trim panel on armrest), but the tool I have to pop the door pane just flexes and just won't budge the clips! The panel has 6 decent sized interior clips holding it on now (panel never removed before). I'm trying to use a fairly cheap Toldeo tool (thin metal and boomerang-shaped) that slides over the interior clips (along with a torch to see through the gap and see the clips) - the tool just flexes though - doesn't seem to be up to it!

The car is a 2009 Passat CC (assuming fairly similar to Mk5 Golf; CC forum not frequented by many).

Does anyone have a recommendation on a specific tool/s?

[Lucas_R]

I removed the door trims on my Mk6 Golf several times to replace speakers and never had any issues getting the clips out (although they are brittle and some broke and had to be replaced). I used the standard plastic/nylon trim removal tools

Gives its winter time and they are cold and hard, can you try putting some warmth on them with a heatgun or hairdryer to soften them up which might help them pop out.

See links to the tools below. I just used the Kincrome tools when I did my speakers. But I have since purchased the metal Toledo tool which has some more strength and leverage to it.

Kincrome Trim Remover Set 5 Piece | Supercheap Auto

Toledo Trim Removal Set 2 Piece | Supercheap Auto

[Deep Blue]

Okay, this is what I have:

https://www.repco.com.au/en/tools-equipment/automotive-tools/interior-panel/toledo-trim-removal-tool-313293/p/A9514155?kwSearch=trim%20tool

Levering the inside door panel with a thin electricians screwdriver (has a thin plastic sleeve on the shaft so won't damage the door/panel) then using a torch to find the clip and sliding the wide end of this tool over it. When I apply prsessure the tool flexes and then springs out. Just won't budge the clip (trying on the bottom two of the six in total). Might need that screwdriver-like popper tool you've shown - looks more sturdy and won't flex!

Thanks for that! Seen a lot of these on aliexpress for $3-$4, but might buy local from Supercheap or Repco.

[Guest001]

The B7 Passat has a plug right in the centre of the door so I presume yours may also have it. I couldnt get one of those tools in far enough so I used a long heavy screwdriver in beside it and twisted it to pop it off

If you break any you can buy them on ALIExpress for about $4 for 10. You also have to pop them up so the outside is right up against the little bulb at the end before you put them back or they wont go in the hole.. Ask me how I know. Put the fork shaped tool in under the THIN washer and lever the whole thing up the centre shaft

This might help you sort through it However the plug i found isnt shown but was there on both front doors

Polo Manual – Google Drive

Polo Passat and MK 6 Golf are all in that folder Have fun

[Deep Blue]

I'm using this video as a guide:

How to remove the front door panel Volkswagen Passat CC - YouTube

I have a 2009 VW Passat CC - I'm doing the driver's door, whereas here it shows the front passenger door (LHD).

I removed two T20 screws on the underside of the panel and two T30 screws hidden in the armrest - exactly as shown on the attached video. Also removed the electric window control panel and the small plastic rivet (shown in this video), and now onto the six interior clips (three down each side). This Russian bloke in the video uses hard plastic pry tools to remove the interior clips. Might try a fourth time, otherwise will have to buy one of the screwdriver style door panel poppers or something that doesn't flex - the thin metal tool I have just flexes and then springs off - just won't pop any of the clips!

Just wondering if there is another screw/screws hidden somewhere - maybe behind the brushed aluminium strip up towards the window???

Thanks for your help so far!

[Deep Blue]

Okay, thanks Lucas_R - may get the metal Toledo tool. I have that other metal Toledo tool, but it doesn't seem to have the strength or leverage - better suited to the more easy stuff. Maybe a hard plastic would also do the trick as shown in the video I found).

[Lucas_R]

Okay, thanks Lucas_R - may get the metal Toledo tool. I have that other metal Toledo tool, but it doesn't seem to have the strength or leverage - better suited to the more easy stuff. Maybe a hard plastic would also do the trick as shown in the video I found).

Yeah that one you linked to above looks quite weak and it would flex/bend easily. I have never seen one like that before. It might work well in some instances but I dont think its the right tool for this job.

Just grab one of those tools I linked to above - otherwise you will be waiting a month for stuff to ship from Aliexpress.

[Deep Blue]

Thanks Hillbilly!

[Deep Blue]

Yeah, you're right - the tool I have is not really made for the stronger clips on the door panels - it just bends, only good for those little plastic exterior clips! I've stuffed things up in the past by using a tool that wasn't suited for the job! Will get one from Supercheap - give myself a good chance by using a better-suited tool!

Just hope there isn't some other hidden screw/s - don't think so! So many variations with VW doors between models and years!

[Guest001]

I'm using this video as a guide:

How to remove the front door panel Volkswagen Passat CC - YouTube

I have a 2009 VW Passat CC - I'm doing the driver's door, whereas here it shows the front passenger door (LHD).

I removed two T20 screws on the underside of the panel and two T30 screws hidden in the armrest - exactly as shown on the attached video. Also removed the electric window control panel and the small plastic rivet (shown in this video), and now onto the six interior clips (three down each side). This Russian bloke in the video uses hard plastic pry tools to remove the interior clips. Might try a fourth time, otherwise will have to buy one of the screwdriver style door panel poppers or something that doesn't flex - the thin metal tool I have just flexes and then springs off - just won't pop any of the clips!

Just wondering if there is another screw/screws hidden somewhere - maybe behind the brushed aluminium strip up towards the window???

Thanks for your help so far!

There is a plug that sits in a vertical groove up hear the top and after you get all the others loose you have to pull the card vertically to get that one out and then card comes off.

I had trouble getting the Tiguan ones to pop and got a piece of metal bar 45 x5mm and slid that in by each one and popped them off

[DonDubber]

Hi Deep Blue,

Ah the delights of VW door card removal I've enjoyed removing door cards/clips occasionally from Golf 6, Golf 7 & Tiguan mk1, and still have some mainly minor physical & mental scars from early encounters.

I guess your CC will have similar plastic clips to these VW models, which are in effect a type of push lock rivet. They have an inner push in/pull out mushroom shaped stem which clips into the door card, and an outer mushroom shaped spreader rivet type design which locks into the hole in the metal frame of the door panel when the inner stem is pushed in by pressing in on the door card on assembly.

I've found the trick to removing these clips without breaking/deforming the door card is to use a two pronged fork wedge shaped plastic trim removal tool to slide between the door card and the metal door panel and then directly onto the middle section of the plastic clip to push/pry the inner part of the clip up/out about 5mm from its locking position in the outer part. When this is done, the whole two part clip still attached to the door card should lift out from the hole in the metal door panel fairly easily without too much extra force needed.

Attached photos show the rivet type clip both closed in the locking position, and open/extended in the removal/reassembly position. The type of removal tool which I've used successfully is also shown. There is a VW special tool set (of course) which is the black one pictured - this one is a Chinese version (of course) which I got from eBay for about $20 for three different wedge/fork types.

There are also a couple of good YouTube short videos on Golf mk5 door card removal (Google) which show the two part clips and how to pull these out, some techniques are a bit rough but seem to work without damaging anything.

Regards, DonDubber

[Deep Blue]

That's fantastic DonDubber!!! Really appreciate such a detailed post! It's clear so many modern cars are built to deter the DIYer and force people to go to the stealership! I just plug away and eventually get there with help from forums. Want to change the door lock actuator (I have one from the wreckers) - wife said to me, "You should be able to fix it in 15 - 20 minutes?"

[Deep Blue]

Okay, picked-up the trim remover (panel popper) yesterday - it looks good - strong with a nice handle.

Anyway, here's the bad news:

My son went and accidentally locked the car!!!

This time around I just can't seem to open the driver's door from the inside or outside (all other doors fine). Any ideas/tricks?

(Need to open the door in order to change over the actuator)

[JustCruisn]

Use the physical key to unlock, you may need to remove a small trim piece first to expose the lock depending on your model.
Turn it a lot further than your probably expect, it should unlock.

[Guest001]

What have you disconnected in the door. If possible hook it back up. If you havent got the card off it should still open with the inner handle