Door Handle

I removed the plastic exterior of the door. The plastic exterior has to be pried off. The handle is fastened to the new exterior plastic face, and this is snapped on.

I opened the door to the microwave, I removed any screw visible with a screwdriver that's behind the door itself. Next you need to get inside of the door frame, so you need to slip something thin, like a metal putty knife in between and slowly pry it open, it comes out real easy. Now the screws that hold the handle are visible and easily reached. When your finished replacing the handle, carefully squeeze with your hands the two pieces together again and put back the screws. Thats it.

Used flathead screwdriver around the interior edges of the front panel to pry off the front panel. The handle comes with it and along with a glass panel inside. Pry off that glass panel and transer it to the new front panel and pop it back in. I removed the two screws from the cracked handle and used them to install the handle to the new front panel. But, before this I added a couple of plastic washers to hopefully distribute the load better against the front panel and maybe prolong the life of the repair. I cleaned the interior glass, since that's hopefully the last we'll ever see of it. Take the whole assy and just snap it back in place on the door. This $100 in parts probably saved me $600-700 for a new microwave / over-oven install charge.

KitchenAid Microwave [Model: KHMS 145 JBS-0]Door Handle Repair
Tools and Parts
• Door Handle [Part # PS390101]
• Putty Knife
• Phillips Screwdriver
• Tray (cup) for parts during disassembly/reassembly (3 screws on door; 2 screws on handle; spacer on top-door edge).
Instructions
• Preparation
o Disassembly can be managed with the door mounted on the unit. The handle is attached by 2-screws that can be accessed only by separating the outer/inner door panels.
o Before starting the project, watch the Youtube.com video for a GE Microwave, which is the most applicable video for removing the collar [i.e., plastic bezel around the viewing window on the inner door) and for separating the outer/inner door panels ].

• Remove the collar
Photo 1: Inner-side clip (bottom of collar) used on
3-sides of the collar (top edge is a spacer) Photo 2: Hinge side clip (right edge)

o As indicated in the video, small clips are on the inner-side of the collar on 3-sides (top, bottom, and open-door edge).
o The clips are on the outside of the collar for the door-hinge side.
o These clips are small and somewhat fragile – once a few are popped, finger pressure will generally pop the remaining clips.


• Separate the outer/inner door panels

Photo shows the inner/outer doors separated, and the 3-screws removed.
o Remove the 3-screws on the door edge before separating the outer door panel.
o There is a plastic spacer on the top, outside edge of the door that is not cemented. Remove the spacer after separating the door panels.
o Use a putty knife to pop the clips for the outer-door panel around the top, bottom, and open-door sides.
o The top door corner (the spacer edge) is tight and should be gently pushed back.
o The outer door panel will remain attached on the hinged edge and function like a second door – move gently.
o The viewing glass is clamped in place; but, handle with caution.

• Remove the Door Handle
o With the outer/inner panels separated, remove the two screws holding the handle and remove the handle.
o Retain the screws for later use.

• Install the new Door Handle
o Reuse the original screws (Note, [Part # W10841091 – screw] is a different thread, and is not self-tapping)
o The door-handle screw holes are not tapped; so insert the old screws in the handle to tap before installing the handle, leaving approximately 1/8 - 3/16” exposed.
o Remove the screws and reuse to install the handle.


Comparison of 2-original screws vs. replacement screw (note thread gauge differences).
• Reinstall the Outer Door Panel
o Align the spacer with the inner-panel edge in the upper corner.
o Close the outer panel, gently snapping the clips into place.
o Reinstall the 3-screws on the door edge.

• Reinstall the Collar
o Snap the hinge side in place.
o Gently snap the remaining sides in place

Had left the small break in the handle go too long, There fore the screw holes in the door had wallowed out. Had to put some small washers in to bridge the wallowed out screw hole. The ends of the handle had broken off on the end of the mounting screws, had to use pliers and the screwdriver to get the plastic mounts off. There was enough room for the washers so no additional adaptation was needed. It all went back together very easily.

After taking the three screws out of the side of the door, I actually had to get help from my Dad who came over and was able to pry the top corner of the door out of the casing. I was afraid I was going to break the door. Once he got the door pried apart, I was able to replace the handle, clean the entire door and quickly snap it back into place and then replaced the screws.

It's a simple repair but costly. Just open the door remove the three screws on the side of door. Now use a small screw driver or metal putty knife to remove the chooker collar around the door " be careful this can easly be broken". Okay now the metal inner door is easier to remove if you slightly bend the tabs up around the door. Look carefully you should be able to see where they catch. Once you do that carefully seperate the outter door cover. Careful sometimes it will pop right out and fall. Please no more further repairs needed. Just screw in the new handle push tabs back out on the metal inner door then snap everything back together and reinstall the three screws.