156 - door check straps
I've seen a few comments & queries concerning door check straps - noisy/ creaking etc. For what it's worth here are my recent experiences with my 156 SW 2001 M/Y with 63K miles. I replaced the OSF door check when the clicks and clonks became really annoying.
The latest issue replacement is a modified design and much improved on the first version. Operation is completely silent and the upgrade is really worthwhile. Alfa P/N is 50503485.
Follow instructions as per eLearn which are 100% correct and without unmentioned snags. Briefly the instructions are :
1. Remove window switches housing – note connector colour codes.
2. Remove door handle surround – prise out screw cover, remove S/T screw, open handle, slide surround fully to rear and pull outward to remove – beware the 2x front lugs.
3. Remove speaker grille (be careful – easily broken – very brittle plastic).
4. Remove speaker.
5. Remove triangular trim cover (prise outward with great care – again very brittle plastic).
6. Remove door card (2x S/T screws in speaker aperture, 2x M6 bolts in door pull aperture, perimeter plastic fir tree studs).
7. Gently and gradually unpeel foam moisture membrane from door vertical front edge, and about 20cm of the top and bottom where attached. Fold back and retain with masking tape. If removed very carefully the adhesive remains undamaged and sticky - the membrane can be reattached as per new.
8. Loosen 2x torx screws (1x upper, 1x lower) securing the vertical front window guide – I removed the lower screw, but fully loosened the upper whilst not removing it).
9. Loosen and remove 2x torx screws holding body A-post pivot bracket.
10. Loosen and remove 2x torx screws holding door check assembly to door.
11. Push aside window guide to allow removal of the door check from inside the door.
Reassemble in reverse sequence, but take note of the following :
The new door check is very stiff. You’ll have to adjust the angle of the A-post pivot bracket with pliers until the torx screws can be safely replaced.
Ensure the rubber outer door check seal is replaced correctly. Refer to the opposite door if unsure.
Alfa hard interior trim self tends to self destruct on disassembly unless you’re really careful. No doubt you’ll find broken parts where some clutz has been there before. Here’s a list of various related items :
Fir tree studs (securing door card) P/N 7739801
Bush for studs (press into door) P/N 60654116
On my car the OSF door pull moulding (E/W switches housing) had been overtightened previously and one of the captive washers at the bottom had been broken out from the plastic. These mouldings aren’t available separately (ie without the window switches) from Alfa. I found the missing broken pieces of black ABS in the base of the door and managed to glue them back onto the moulding.
On examination I found my old door check was worn along the flat arm where in contact with the roller/s. The plastic bushes in the body aperture bracket had completely broken up and caused up/down play between the arm and the bracket. Most of the clicking/clonking noises from the old door check had been caused by that movement and the general service wear and tear. The spring tension is extremely strong so any wear and excess movement is exaggerated by this. Nothing was seized, broken or loose. The later design (50503485) is a much better part.
This replacement applies to all 156. ePer shows different check straps used on the 147 and GT but the general method may be similar.
I hope this helps anyone with similar annoying door check straps. The job took me a couple of hours but having replaced one I reckon this could be reduced to around one hour.
Good luck !