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 Old 10-20-2015, 10:06 AM   #1
 
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Default How to fix trunk release handle sticking / stuck / stiff / broken

I think this will be a problem many people will start to have as they reach 100k.
New handle part # is D35062410B can be had for ~$30 + shipping or $36 shipped on ebay
Parkmazdaoemparts.com has free ship on over $200 so even though part prices are a bit more if you can get free shipping it still costs less thru them.

Remove trunk release handle:
  1. Take of trunk lid interior trim / liner:
    • Pop out the 15 or so trunk lid trim fasteners using a butter knife or something.
    • Remove handle (clipped in on sides).
  2. Remove the trim piece above the license plate (covers handle/license plate lights):
    • Two (2) - 10mm nuts on lock cylinder:




    • Two (2) - 10mm nuts for trim.

      DS:





      PS:





    • Clip for wires that go to unlock button on GT model


    • Clip for trim on DS.


    • Plug for lock button on GT model.


    • License plate lights do not need to be removed. Pull trim off and place upside-down on top of open trunk by emblem.


  3. Remove trunk release handle:
    Pic from outside:

    • Unclip lock assembly rod by sticking small flathead screwdrivers above and below this white plastic clip and pry to press down prongs and pull rod out to release white clip from handle.


    • Two (2) 8mm nuts.




  4. Replace trunk release handle and put back together.*

* I repaired mine. You just need a rod with 4mm (5/32"=0.15625") OD that is about 100mm (4") long or m4 or 5/32 threaded rod see if you have a cheap screwdriver that has the right OD...
IDK if 15 (part # B45558411) is just the spring or the spring and rod or what:
2006 Mazda 6 Parts - Discount factory (OEM) Mazda parts and accessories at Park Mazda OEM Parts
This should work:
Dimart 45# Type Stainless Steel CNC Round Rod 9" x 5/32" Silver Tone - - Amazon.comDimart 45# Type Stainless Steel CNC Round Rod 9" x 5/32" Silver Tone - - Amazon.com
If you find a rod this is how you can repair the handle:
  1. Undo the spring by prying it out of slot on metal bracket.
  2. Grind down the punched ends of the rod on both sides.







  3. Pry metal bracket up over the rod and remove. Use a crescent wrench to pry one side up.





  4. Bend bracket back into shape. Use crescent wrench or pliers. Do not distort. Make so ends are perpendicular and center is straight.
  5. Cut the rod and remove. I cut the rod a 2nd and 3rd time close to each end so I could tap the ends out as they are so rusted they wont pull out.







  6. Wire brush and paint.
  7. Cut rod to length:


  8. Cut slots in rod ends. Bend one end to hold rod in place. Or weld a bulge, or one of those metal clips or just a zip tie or use a nut if find threaded rod...this is just what I did to hold rod in place.





  9. Insert rod thru bracket, handle and spring.



  10. Bend other side or rod.


  11. Reattach spring.



  12. Test that handle moves freely and returns to closed position.


  13. Install.

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Last edited by aviator79; 10-20-2015 at 10:46 AM.
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 Old 10-23-2015, 04:31 AM   #2
 
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Toooooooo much work, I fixed the problem by simply washing out the handle area, then spraying silicone lubricant up near the springs on either side, the working it in by rocking the handle back and fourth until it got smooth..

Did mine several months ago and still works as new now.

Before the handle would not "return" after pulling it to unlatch the trunk.
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 Old 11-13-2015, 07:47 PM   #3
 
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Thanks for "how to do" Did mine today.
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 Old 05-02-2017, 03:30 AM   #4
 
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Hi! Does D35062410B fit regular Mazda 6 (2006-2007) aswell or only Mazdaspeed? I'd say they're the same but I'm not expert.
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