How to remove door sill properly

[ptimko]

So I attempted to remove my door sill to allow me to easily test fit my modified foot rest (I filled the space behind the foot rest with Great Stuff). But in the process I broke the door sill. Now that it is out, I can see that there are three clips that hold it in place, one on either end and one in the middle. But even with the door sill removed these clips are tough to get out.

Is there a good way to remove the door sill so that it doesn't break?

Thanks,
Paul

[Randy Forbes]

Pull straight up.

That's actually the threshold trim piece (BMW may even have other names for it) "the sill" is what that piece attaches to. Makes a really big difference to the guy on the other side of the parts counter, when you say you want "a sill" and it involves cutting and welding to install.

So to correctly answer your question. "how to remove door sill properly?" The answer would be with a plasma torch. Big difference to what you really wanted...

[BimmerBreaker]

If you want to be really careful about it use 2 plastic trim removals tools

Pry up at the front slowly, once its loosened, wedge a trim removal tool under it and leave it (otherwise when you pry up at the rear it will re-seat the front)
Use the other trim removal tool to pry at the rear edge. Once its loosened, pry straight up from the middle

I cant think of a way more careful than that to remove it

[pacethis]

If you want to be really careful about it use 2 plastic trim removals tools

Pry up at the front slowly, once its loosened, wedge a trim removal tool under it and leave it (otherwise when you pry up at the rear it will re-seat the front)
Use the other trim removal tool to pry at the rear edge. Once its loosened, pry straight up from the middle

I cant think of a way more careful than that to remove it

What he said...unfortunately, sometimes it's going to break no matter how careful you are....

[crashgordan]

getting ready to go through this same process. my dead pedal is cracked and useless.
planning to reinforce the back of the replacement as well.
fingers crossed on a safe "threshold trim" removal.

[ptimko]

The price of replacement parts isn't too bad if you break the sill.

My dead pedal feels much better with the foam behind it.

Paul

[crawfordbay]

Also looking to reinforce my dead pedal. How did you apply the foam?

The price of replacement parts isn't too bad if you break the sill.

My dead pedal feels much better with the foam behind it.

Paul

[ptimko]

I used the "Great Stuff" expanding foam and just sprayed it in the empty space behind the dead pedal (while it was removed). The foam is very sticky. Once the foam hardened, I cut off the excess. Very simple. Very low tech.

Paul

[Vintage42]

The foam could expand into a wider area than just under the dead pedal. I think the dead pedal is part of the carpet, and there's a wiring duct and harness under that area. The carpet, dead pedal and the wiring likely gets encased in the solidified foam.
I wonder if there is a more elegant solution of lifting the carpet and spot gluing something to shim the backside of the dead pedal.

[BimmerBreaker]

The foam is applied with the dead pedal completely removed

[BMWBergy]

The foam could expand into a wider area than just under the dead pedal. I think the dead pedal is part of the carpet, and there's a wiring duct and harness under that area. The carpet, dead pedal and the wiring likely gets encased in the solidified foam.
I wonder if there is a more elegant solution of lifting the carpet and spot gluing something to shim the backside of the dead pedal.

As breaker said, foam is applied after dead pedal is removed. The dead pedal is NOT part of the carpet, it's part of the kick panel trim, and the space behind it is mostly a void.

[crawfordbay]

Thanks for the advice. I took pictures as I went and made a guide. I’m not saying this is the best method ever conceived, but it worked for me. Nice and firm now.

Reinforcing the Dead Pedal Foot Rest with Spray Foam
https://www.facebook.com/media/set/?...1&l=c6c8ee1c52

[Terry F.]

Interesting product. Good to know about, thanks!

Sent from my cracked-screen Samsung Galaxy 6 Edge Plus.

[crawfordbay]

image.jpeg

This is what it looks like underneath the dead pedal for anyone who hasn't seen it. (The lines on the floor are not a protrusion, just indentations in the carpet where the pedal touches.)

[DBWard]

Does the threshold trim have to come out to replace the dead pedal? Please advise.

[rasmuw]

Does the threshold trim have to come out to replace the dead pedal? Please advise.

Yes. The dead pedal panel has to lift up to clear a lip on the A-pillar.

[DBWard]

Yes. The dead pedal panel has to lift up to clear a lip on the A-pillar.

YMMV but I did not need to remove the threshold to remove the dead pedal. Will report back if there’s a problem with reinstall.

Thanks too to the folks who offered the expanding foam DIY, especially Crawfordbay. Very helpful...

[DBWard]

YMMV but I did not need to remove the threshold to remove the dead pedal. Will report back if there’s a problem with reinstall.

Thanks too to the folks who offered the expanding foam DIY, especially Crawfordbay. Very helpful...

Just closing this out for reference purposes and possibly the next person to pursue the mod or replace the dead pedal... Again, YMMV, but I did not need to remove the threshold trim to remove or install my new, foam backed dead pedal, which is nice and solid now. A great little low cost mod to keep one more plastic bit from breaking/cracking/disintegrating prematurely.

[rasmuw]

YMMV but I did not need to remove the threshold to remove the dead pedal. Will report back if there’s a problem with reinstall.

After further inspection, I agree. The lip on the bottom of the dead pedal panel is not all that big, and there is no screw holding it to the metal underneath. I was confusing it with the rear panel that extends under the threshold and IS held by a screw.

I did the foam backing for the dead pedal as well. It works great!

[Mr Bingley]

Thanks for the advice. I took pictures as I went and made a guide. I’m not saying this is the best method ever conceived, but it worked for me. Nice and firm now.

Reinforcing the Dead Pedal Foot Rest with Spray Foam
https://www.facebook.com/media/set/?...1&l=c6c8ee1c52

Hey, great write up--you should post it here as a separate thread from this so it can be included in the FAQ and turn up in a search. No one will ever find it in a thread titled "how to remove door sill properly."

[Evergreen Dan]

I'm doing this now. I press quite hard on the dead pedal to get into my 6-points, so I've cracked two already. For this one I cut a piece of 3/4" high-grade plywood to back up the dead pedal. Quite a lot of trimming and fussing, including cutting slots for the plastic ribs to go into to. I used tub surround adhesive (because it goes from plastic to wood) to glue the plywood in place and I plan to foam underneath that to support the plywood from the floor. I hope this is the last time I do this job. Grateful to @crawfordbay for the how-to.

[35nhma]

Yes. The dead pedal panel has to lift up to clear a lip on the A-pillar.

The dead petal prong that inserts under the door threshold trim can be pried out with a plastic trim tool w/o removing the threshold trim. I have done it twice, and am about to do it again. I'm not saying this is the best or proper way, but I read a lot of stories about breaking the door sill (i.e. this thread) so I have steered clear of it.