Door handle ? What to do ?

[1951M1078]

So I walk out to the truck and click ? Door will not open.

Oh, know the dreaded broken door handle. (much crying)

I removed it from the door and , yep broken lever. (dam)



How about some JB weld ? And some wire set into the JB weld ?

Under the JB weld is a pic of .040 SS safety wire just for luck.

Took a look at the part and found their is much room for improvement.
Added for filler and filled it to fit. I think we all need to pull the door handles and add this to the ones that have not broken.

 

[1951M1078]

And here it is installed.



Think I will take it to a lock smith and have a key made also ? LOL Almost can't see the brake .

 

[1951M1078]

The biggest problem will be the black ends to the end of the rods. Will need to find something to replace them ?

Now on to the next think that will brake ?

 

[coachgeo]

... black ends to the end of the rods. ....

hmmmm........ can you retry explaining? This makes no since. Are the "Black ends" some sort of clip that is located at the end of a rod? Maybe a picture or drawing will help for those who have not yet seen inside their door much less looked close hand at their door handle system?

On mine the chrome handle you pull to unlatch when outside the vehicle is missing. I've got no clue yet if other pieces inside the door are missing too. It closes and latches fine. The handle to open it from inside works fine. Am nimble, so just been crawling into the truck from passenger side. Do plan to fix door eventually though so interested in your work on this.

thanks for the pics. Look forward to updates.

 

[1951M1078]

When I get it back from the locksmith and install the control rod's I will take some photos of the plastic ends.

Just a note,when removing the door handle you must remove the control rod's first. This is where the plastic falls apart.
I got a PM about parts and will ask if he has the ends ?

 

[Awesomeness]

I think ScottMandu has some of the plastic ends.

 

[coachgeo]

In here in a thread somewhere is a note where someone who found a generic replacement for the ends if I recall right.

Question.. can one take a Dremmel tool and score around the rod with a deep enough groove to insert a small Circlip into as a way to replace the piece that causes some much fret here. Have not seen these rods so that is just a wild guess.

 

[aleigh]

In here in a thread somewhere is a note where someone who found a generic replacement for the ends if I recall right.

Question.. can one take a Dremmel tool and score around the rod with a deep enough groove to insert a small Circlip into as a way to replace the piece that causes some much fret here. Have not seen these rods so that is just a wild guess.

When I did my door repair (exterior handle), I didn't even have the plastic end on the door handle side. I checked my driver side (intact) and it didn't have them either. The lock rod did have them. You can get generics for steel rod of various OD (I ended up having to fabricate a rod too, mine was missing) but I think you are fine without the plastic.

 

[scottmandu]

The biggest problem will be the black ends to the end of the rods. Will need to find something to replace them ?
Now on to the next think that will brake ?

I stock those plastic pieces, and they are white now. However they are expensive little buggers. There was also someone who had those lever pieces cast. I'm working on a billet steel replacement.

 

[scottmandu]

In here in a thread somewhere is a note where someone who found a generic replacement for the ends if I recall right.

I've tried 30 different samples of those lock pieces from a dozen manufactuers and none worked. I ended up getting them from Steyr.

 

[aleigh]

Not to beat a dead horse here after my earlier post... but if you look in the -24P it makes no mention of the plastic things either. And mine has not fallen out after thousands of miles and all the jostling. I've also seen plenty of other applications without them. This is why the rods are hooked on the end (or my intact one was anyways).

 

[1951M1078]

My truck has them on both sides.

 

[scottmandu]

There are 4 plastic clips on each door, and they hold the rod to the internal lock mechanisms. The other end is usually mechanically held in place but the rod itself. They are number 22 in this illustration.

 

[coachgeo]

There are 4 plastic clips on each door, and they hold the rod to the internal lock mechanisms. The other end is usually mechanically held in place but the rod itself. They are number 22 in this illustration.

View attachment 709100

The ABSOLUTE BEST route to go is use OEM clips that Scott sells to replace ones you have.

If your a cheap bastard....and only need ones at the lock/latch end (which is all I see in diagram above).... you can modify your lock/latch by enlarging the clip holes with a #1 drill bit ( .228 ). to match generic clips found at auto parts store. Make sure that size bit fits the generic clips you pic up. For me two packs of generic clips was needed to complete one door. Scott mentions 4 clips per door ..... but I only see three (two #22's and one for end rod #25). I could be blind and 4th is hiding from me?

From the assortment packs I used the Black pieces shown in pic to replace each of the #22s and the one white clip shown in pic replaces the one for end of Rod #25. Interestingly.. above diagram does not give a number/label for the plastic clip at end of rod #25

Anyone see a 4th clip in the above diagram?



Anyway... worked for me.....

oh and thanks FMTV Sales for the used handle to replace my broke one. Was very reasonably priced.

 

[Pointman0853]

I will soon have a set of stock A-o door handles that are keyed for sale.

As soon as the FMTV parts guys have the upgrade kits back in stock that is...

Pointman

 

[snowtrac nome]

For me its the door handles that are breaking. I had one break this winter and now the replacement has broke.

 

[coachgeo]

For me its the door handles that are breaking. I had one break this winter and now the replacement has broke.

where did it break?? My door "handle" was broke when bought it. one leg of the handle broke it appeared and rest wiggled off.. rest of mechanism was fine besides the plastic clips disintegrating. curious of a slab of JB weld should be applied to the working handles at some spots in the unit to add more rigidity/strength to help prevent breaking?

 

[Crapgame]

My local locksmith charged me $50 to cut 4 keys to fit my existing driver door latch and to match the wafers in the passenger door which had a different lock code

 

[scottmandu]

Check your door catches, often they get worn, damaged, or dirty and put additional stress on the handle. Fixing or replacing the handle without addressing the root cause will result in a broken handle.

 

[1951M1078]

Just a update. My repair broke. I tried.

So I cut a new lever out and things are all better.



Also tried to order new ones with no luck. Guess the new kits are all sold out ?