Fixing a Broken Side Mirror on an Alfa Romeo, Fiat, or Lancia (by Capitan Farloc)

A broken side mirror might seem like a small issue, but it can be dangerous—and even get you fined! If you drive an Alfa Romeo, Fiat, or Lancia and your external mirror is damaged, don’t rush to the garage just yet. In this step-by-step guide, we’ll show you how to disassemble, repair, or replace it using simple tools and a bit of DIY spirit. Save time and money, and get your car back in perfect shape!

I Found the Side Mirror of My Alfa Romeo 156 Broken 

One day, I went to pick up my Alfa Romeo 156 from the car park and had the unpleasant surprise of finding the passenger-side mirror broken at the hinge. It was dangling, held up only by the wires of the electric controls.
At first, I thought it might be the work of a vandal or some prankster who had fun hitting it to break it, or maybe someone accidentally knocked it. However, as we’ll see later, the clip holding the two parts together could have come undone over time simply from repeatedly folding and unfolding the mirror when parking the car on narrow streets.
I should mention that I’ve found the same hinge system on the Fiat Panda, so I assume it’s used in the same way on all Alfa Romeo, Fiat, and Lancia cars from a few years ago.

Temporary Fix

To avoid losing the side mirror while driving, and above all to keep using it, I secured it temporarily with adhesive tape. My plan was to disassemble it as soon as possible to attempt a proper repair. 

Removing the Side Mirror from the Door

The first step in repairing the side mirror is to detach it from the car door so you can work freely and comfortably on a workbench.
To remove it, you'll need to take off the plastic cover located on the inside of the door. I used a screwdriver for this task, being very careful. However, if you have specialised plastic tools designed for prying car interiors, those are a much better option as they are virtually guaranteed not to scratch the paint.

Once the Plastic Cover is Removed

Once the plastic cover has been taken off, you will have access to the hex-head screws that secure the side mirror to the car door. Next, you'll need to unscrew them using a wrench or a socket spanner, while carefully disconnecting the electrical connector for the mirror adjustment (or mechanical controls if it's manually adjustable).

Removing the Mirror Without Breaking It

Now, with the side mirror placed on your workbench, you can begin dismantling the internal components.
The first step is to remove the mirror itself, which is attached with plastic tabs (the ones marked with red circles) to the internal adjustment system.
To do this, you'll need to push the mirror all the way to one side to create a gap on the opposite side. Then, you can insert a medium-sized screwdriver into the gap and gently lift one of the tabs to unclip it. Hold the mirror to prevent the tab from reattaching and repeat the same process for the second tab. Be warned, this task isn't the easiest—if you apply too much force, there's a risk of breaking a tab. However, if that happens, you can purchase just the mirror itself from an auto parts shop. Non-original replacements are generally very affordable.

Disassembling the Internal Parts to Access the Hinge

The area we need to reach is the hinge that allows the side mirror to fold. The two components that exert pressure on this hinge are made of metal, but to work on them effectively, we’ll need to remove (as much as possible) their respective plastic coverings.

Disassembling the Mirror Adjustment System

With the mirror removed, you can now access the adjustment system, which in my case is electric and controlled by two small motors.
The unit is secured by three screws (marked in red), but it’s not necessary to detach it completely. You can work on it while leaving it fixed to the bracket. However, it’s the bracket itself that needs to be removed by unscrewing the cross-head screw located on the right-hand side (as shown in the photo).
Once this is done, you’ll be able to slide out a part of the metal hinge—the "broken" part—just enough to work on it effectively.

Removing the Hinge Cover on the Door Side

Now, we also need to free the other part of the hinge, the one fixed to the car door. To do this, you simply need to unscrew the three screws located underneath. To better understand the photo, the part with the "Magneti Marelli" label is the underside of the side mirror, while the section with the three screws is the bottom part of the piece that remains attached to the door.

Let’s Analyse What Happened

Now that we’ve freed the hinge, we can take a closer look at what happened. The two metal parts that make up the hinge are held together by a spring, which is secured in place by a toothed locking washer.

The Hinge Is Made Up of the Following Components

A) The metal part that attaches to the car door. 
B) The metal part that remains attached to the side mirror.
C) The spring that holds the two hinge pieces together.
D) The protective washer.
E) The self-locking toothed washer that secures the two hinge pieces with the spring sandwiched in between.

This steel washer has inward-facing teeth that are slightly bent, allowing it to be inserted into its slot by following the direction of the teeth's curve. Once the washer is in place, the spring, which applies pressure in the opposite direction, causes the teeth to close, locking the washer.
Unfortunately, this "self-locking" washer, subjected to significant stress, popped out, causing the hinge to open. Even after attempting to refit it (which, naturally, I tried), it fails to lock properly and, after a few days, will pop out again.

An Alternative Solution for Fixing the Side Mirror

Since the inside of the hinge is hollow, I came up with an alternative solution. Instead of securing the spring with the external locking washer, I decided to use a bolt that passes through the inside. Here’s what I gathered for the repair:

• An M8 bolt (8mm diameter) that’s 50mm long.
• Two M8 nuts.
• One 8mm washer with an outer diameter of 24mm.
• One 8mm washer with an outer diameter of 40mm.

Repairing the Mirror Hinge

The smaller washer will go on the bolt head and must fit into the slot of the hinge piece attached to the car door.
Once the other hinge piece and the spring are positioned, the larger washer and a nut will be placed onto the bolt.
By tightening the nut with a wrench, the spring will be compressed without requiring additional tools.
Once the bolt is fully tightened, a second nut (as a locknut) will be added to secure everything and prevent it from loosening due to movement.
After this, you can reassemble the rest of the side mirror, excluding the locking washer and the protective washer that were previously used, as they are no longer necessary.

I hope you find this idea useful, and I can assure you that the side mirror has never come apart again.

Warm regards to everyone!
Luciano (Capitan Farloc)