Jaguar XK8 XKR Door Handle Replacement Seal Tutorial

The problem

The gasket on the door handle is made from plastic which becomes brittle and breaks over time. The seal will then allow dirt and water ingress into the interior of the door card which can affect electrics. It also looks old and parts of the seal can look broken around the exterior door handle.

Symptoms of the fault

Parts of seal missing or broken around door handle, electrical issues with window, speaker or door locking mechanism

Vehicles affected

XJ6 XJ8 XJ12 XJR X300 X308 models 1994-2002 (VIN range 720125 through to 878717, F00001 through to F59525)

XK8 XKR models 1996-2006 (VIN range 000001 through to 042775, A00001 through to A99999)

Suitable for coupe & convertible.

Also suitable for left hand drive & right hand drive models.

Associated part numbers

JLM-12035

Our solution

Our improved design gasket is made from closed cell foam which is water resistant, preventing breakdown from water and dirt making it longer lasting than the original gasket. The gasket is a simple, oval design making it easy to fit.

Our kit also comes with alcohol wipes to clean off any built-up grime from the failure of the OEM gasket, as well as a tube of RTV silicone sealant to stick the gasket to the handle and prevent any future leaks.

You will receive

2 x foam door handle seals

2 x alcohol wipe

1 x RTV silicone sealant

You will need a trim removal tool kit, Philips screwdriver

Firstly ensure the windows are in the furthest upright position, then disconnect the battery.

Using a trim removal tool, remove the rubber mat from the base of the door card, as well as the small leather-covered piece of trim next to the electrical switch pack.

Using a Philips head screwdriver, remove two screws. One is located at the base of the handle towards the back of the door, and the other is located behind the leather-covered trim that was removed.

Disconnect electrical switch pack by gently pulling up on the pack once the screws have been removed, then pull the electrical connector apart from the switch pack.

Remove the interior handle backing by sliding a small, flat trim removal tool into the center circle of the backing. This will expose a screw that can be removed with a Philip's screw driver. Once removed, pull away the interior handle trim.

It is worth familiarizing yourself with the locations of where the door card is secured onto. The green & yellow plastic brackets hold a plastic bolt which pops out of locators on the door frame. We recommend working your way from the door speaker on the upper corner, and working your way round anti-clockwise. Be careful not to break any of the plastic brackets.

Remove the 2 bolts on the inside of the exterior door handle using a 7mm socket and rachet. These are quite fiddly to remove so be careful to not drop them inside the door frame once removed.

Then unhook the handle from the two spindles that attach to the cylinder lock and window motor. The exterior door handle will come off.

Using a pair of scissors, or by twisting the center tabs, remove the OEM gasket.

Fit the new & improved foam seal onto the exterior door handle. To keep it in place you can use the RTV silicone sealant provided. Apply a small amount of the sealant to the back of the foam and firmly press in place.

Clean the door handle recess with the alcohol wipe provided, cleaning away any dirt or residue that might prevent a flush fit with the door.

Perform steps 1-6 in reverse order to reassemble the door of the vehicle and repeat for the other side if necessary. If the seal is not sitting entirely flush with the door, you may place further RTV sealant to the outer edge and wipe away any excess.