I've got a 1995 F-350 that the inside door handle broke off on. I got a new one and took off the door panel and replaced it. But the latch still doesn't like to work. And when it does, you have to pull up pretty hard on the handle, which is probably why it broke in the first place. It broke just a few weeks after I got the truck so I can't say that I remember noticing it being hard to do but maybe I just wasn't used to the truck. Anyway, I'm wondering if there is a way to adjust the sensitivity or something along those lines?

Here is what it looks like

 

I talked to my brother(a mechanic) who owns a 94 bronco and I own a flareside. He said to just lube the hinges, it sounds like it would work.

He also said to check and see if the cable moves freely, mine does, what about yours?

The only thing wrong with mine is that the hinge is hard to move, so lubing might work.

Signed,

a ford truck owner who broke the handle as well.

 

Lubing it hasn't done a thing, but I've noticed that when I close the door, the lower half bends a little outward and then back in. Not sure why that's happening, but it also sits 1/4" out along the mid to lower edge of the door. That might be causing the issue of why the inner door handle can't open.

 

It sounds like your door flexing out at the bottom is your problem. This could be caused by the weatherstripping being loose and maybe sagging down in the wrong place or something like that. I would check your weather stripping all the way around and make sure it is all tight and in the right place. If a piece got knocked off it could be keeping your door from seating where it should and putting excessive tension on the handle. Your door could also be bent in which case I don't know what you would do about that besides for trying to tweak it by hand.

 

Try adjusting the striker in the door Jamb its the easiest place to start ,

 

also check for freying on the cable itself as that is also a common problem...

 

Hmm..I can maybe help here...look at where the plastic cable-housing hooks into the handle mechanism in the pic...take a screwdriver and pry the metal tab the cable is fastened to away from the handle. This will put some tension on the cable..and allow the handle to unlatch the door without having to be pulled so far. Shouldn't take much.

Also..if the door handle mechanism is flexing the door..or loose when you pull the handle..then you need to sturdy the door metal up.

I had to braze a large body washer to the door so my handle mechanism had something sturdy to fasten to.

 

Well I found out my problem, The metal around the hole for the bolt to go into is split causing movement when I pull the handle. Door handle works great without the plastic panel, but otherwise it won't work. Going to try and the splitting welded up.

I only saw this after taking the handle and cable assembly off. I don't know if this is what's wrong with the original poster's truck, but this might be it.

 

If welding the hole doesn't work, here is what I done with mine (97 F350).

I found an "L" bracket I had lying around. Drilled out screw hole to the size of the cable and cut an opening for the cable to fit in.


The I cut it to size



After that I took what was left of the "L" bracket and folded a section about 1/4" in half and pounded it flat and cut it off. Its hard to see it in the vise.



Then I just lined up both pieces on the handle, using the folded piece as a spacer, drilled holes in the pieces and handle, and secured with a small machine screw. This allowed me to move my cable back putting more tension on cable. Door now works great.



I hope this helps.

 

Thanks y'all. 17Z this was a brillant idea, and easy too.

I had all of the above problems including a plain worn out control. As you know this cannot be purchased new, it is only included in a door latch/cable/control assembly for $180.

 

Mine was hard to pull then i sprayed some seafoam deep creep, let it soak for a while and voila. easy now same thing on tailgate hinge.

 

i mean tailgate latch