Go Back   Ford Truck Enthusiasts Forums > Diesel > 1999 - 2003 7.3L Power Stroke Diesel
Sign in using an external account
Register Forgot Password?


1999 - 2003 7.3L Power Stroke Diesel SPONSORED BY:

Welcome to Ford-Trucks Forums!
Welcome to Ford-Trucks.com.

You are currently viewing our forums as a guest, which gives you limited access to view most discussions and access our other features. By joining our community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join the Ford-Trucks Forums community today!





 
Reply
 
 
 
 
LinkBack Thread Tools Search this Thread
  #1  
Old 11-06-2011, 02:04 PM
bigtexan99 bigtexan99 is offline
Elder User
 
Join Date: Nov 2004
Location: Austin
Posts: 682
bigtexan99 is gaining momentum as a positive member of FTE.bigtexan99 is gaining momentum as a positive member of FTE.
SuperCab rear doors won't open. Cable / Latch broken

A while back one of my supercab doors would no longer open. I was able to follow the instructions here and fix it. http://www.ford-trucks.com/forums/91...wont-open.html It worked.

A year or so later, the lower cable broke. Here's how I fixed it.
There is another post with some drilling and rivets. http://www.ford-trucks.com/forums/10...tch-fixed.html
I only used some zip ties and plastic screw anchors.

The main cause of problems with stuck doors is that all the cables use plastic bushings to hold the cable into the proper position. Apparently, this plastic degrades over time and disintegrates, causing the cable to no longer be anchored where it should be. This repair is just re-securing the cables to their proper position.

****
Remove the door panels from the inside, 2 screws at the window. Pull the top half of the door panel off towards you. For the lower panel, there are two 7mm bolts and possible a screw. Remove them and lift the lower panel straight up to remove.

You can now use a screwdriver to unlatch the lower door catch. To open it, you need to leverage the screw driver to mimic pulling the cable. It may take you a couple of times to get it right. If the upper latch is also broken, you can unlatch it by just pulling down on the upper cable. I had to pull down on the upper cable and use the screwdriver on the lower latch at the same time to open the door.


Once the door is open, use a T27 screwdriver to remove the 3 screws at the bottom of the door holding the latch in place. Then you can remove it and work on it much easier.

All I did was cut and trim a simple plastic screw wall anchor to mimic the original size and shape of the plastic bushing. I then used zip ties to hold it in place.

When you have it secured, just remount the lower latch and you are good to go. If you top latch is also bad, you can use the zip ties to anchor the cable in the proper position.

Here are some pics.

The original disintegrated bushing. Use a razor knife to remove it.


The plastic screw anchor used to replace bushing. Cut it to size.


Anchor the plastic screw anchor to the cable with zip ties.


Insert the ball end of the cable to the lower latch and then secure the cable with 1 more anchor.


Used a couple of zip ties to secure the upper cable into its proper place.


Here is a fuzzy picture of the lower latch remounted in the door, with the zip tied cable in place.
__________________
Early 99 F250 SuperCab PowerStroke 7.3 2x4
289k miles and rolling strong. 17/21 mpg
Muffler and CC delete A/C heater core mod
boost, tranny, egt gauges
***
Reply With Quote
  #2  
Old 11-06-2011, 07:26 PM
diesel-fitter-bum01's Avatar
diesel-fitter-bum01 diesel-fitter-bum01 is offline
that guy
 
Join Date: May 2009
Location: Pierce,NE
Posts: 1,452
diesel-fitter-bum01 has a good reputation on FTE.diesel-fitter-bum01 has a good reputation on FTE.
Tyler Murphy
Good info and pics. Thanks
__________________
Tyler
Owner/operator JBI mobile dyno service.
Mine E99 F-350 sc sb 4x4 updated to L99,308K,FF 250's,arp,uppies,T-500,RR,HPX,4" straightpipe,T4/s366,built trans,airdog,swamps hf/hv,fuel sump,melling lpop,water inj,and DP F6 tunes. lots of little stuff. 01 Ex & 02 ccsb
Reply With Quote
  #3  
Old 07-30-2012, 09:57 AM
bradxray bradxray is offline
New User
 
Join Date: Feb 2008
Posts: 11
bradxray is starting off with a positive reputation.
a second similart option to fix the rear door

Did you get your door to work long term? Sounds like the fix on this page combined with the info in the video below should fix my problem. I had the same problem with my upper latch. Turned out to be a broken cable sheath. I wouldn't think the zip tie would work long term, but it is worth a try. This guy made a video about a different way to fix it. I haven't tried it yet. Just looking around for ideas before I start. But I know I don't want to pay $160 for a new latch and then have the other 3 break also! Be sure to click a few ads if you like the guys video. It was a three part video. Takes a little effort to rig yourself. I think the bottom cable is pretty similar. ford super duty rear door wont open part 1 of 3 - YouTube
Reply With Quote
  #4  
Old 08-02-2012, 06:27 PM
bigtexan99 bigtexan99 is offline
Elder User
 
Join Date: Nov 2004
Location: Austin
Posts: 682
bigtexan99 is gaining momentum as a positive member of FTE.bigtexan99 is gaining momentum as a positive member of FTE.
Yes, my little fix with zip ties and using plastic screw plugs as a bushing is still working fine.
__________________
Early 99 F250 SuperCab PowerStroke 7.3 2x4
289k miles and rolling strong. 17/21 mpg
Muffler and CC delete A/C heater core mod
boost, tranny, egt gauges
***
Reply With Quote
  #5  
Old 01-30-2013, 08:38 PM
volcom521 volcom521 is offline
New User
 
Join Date: Jan 2013
Posts: 4
volcom521 is starting off with a positive reputation.
Found an assembler

I got lucky and found a local company Mako Hose and Rubber Co. They are in South Florida, but they made a custom assembly with brass mounts to prevent them from breaking, which happened to mine. $25 and took them 15 minutes. I found them on the web at www.makohose.com
Reply With Quote
  #6  
Old 03-18-2013, 01:57 PM
Jahken Jahken is offline
New User
 
Join Date: Mar 2013
Posts: 1
Jahken is starting off with a positive reputation.
Latch cable

I went to Mako hose and got both lower cables for $50. the dealer wanted $205 each.Thanks
Reply With Quote
  #7  
Old 07-20-2013, 04:02 PM
MaddieFay's Avatar
MaddieFay MaddieFay is offline
New User
 
Join Date: Jul 2013
Location: San Antonio
Posts: 3
MaddieFay is starting off with a positive reputation.
I recently inherited my grandfathers truck, which has both back doors locked up. I have only opened one up door and it seems to just the be the upper latch. I have taken it all a part and pulled down on the upper cable, but its still not releasing. Any advice on what is keeping it from releasing?
Reply With Quote
  #8  
Old 07-22-2013, 03:17 PM
bigtexan99 bigtexan99 is offline
Elder User
 
Join Date: Nov 2004
Location: Austin
Posts: 682
bigtexan99 is gaining momentum as a positive member of FTE.bigtexan99 is gaining momentum as a positive member of FTE.
It can take a couple of attempts. Try pulling on the cable from different angles, at the same time pushing the door open.

I had to pull on the top cable and use the screwdriver on the bottom latch. It took quite a few times before I got it, but once I did and understood which way the latches and cables moved it was easier to do it again.

Did you review those 2 links I included in the 1st post? They have great pictures and more examples. There is a link to a video in one of them.
__________________
Early 99 F250 SuperCab PowerStroke 7.3 2x4
289k miles and rolling strong. 17/21 mpg
Muffler and CC delete A/C heater core mod
boost, tranny, egt gauges
***
Reply With Quote
  #9  
Old 07-22-2013, 09:08 PM
MaddieFay's Avatar
MaddieFay MaddieFay is offline
New User
 
Join Date: Jul 2013
Location: San Antonio
Posts: 3
MaddieFay is starting off with a positive reputation.
I ended up opening up the opposite stuck door, and fixed that one hoping that it would help me learn about the one that won't open. I had to open and repair both top and bottom latches, but the door that is still stuck only has the broken top latch. I'll give it, and my brain, a few days to rest and see what happens.
Reply With Quote
  #10  
Old 07-23-2013, 10:01 PM
bigtexan99 bigtexan99 is offline
Elder User
 
Join Date: Nov 2004
Location: Austin
Posts: 682
bigtexan99 is gaining momentum as a positive member of FTE.bigtexan99 is gaining momentum as a positive member of FTE.
Good idea, sometimes it just helps to take a break.

If you can't get it open next time, we could meet up and take a look. I'm in Stone Oak.
__________________
Early 99 F250 SuperCab PowerStroke 7.3 2x4
289k miles and rolling strong. 17/21 mpg
Muffler and CC delete A/C heater core mod
boost, tranny, egt gauges
***
Reply With Quote
  #11  
Old 04-30-2014, 03:58 PM
M&RSmith11 M&RSmith11 is offline
New User
 
Join Date: Jul 2011
Posts: 3
M&RSmith11 is starting off with a positive reputation.
Saw this thread searching out how to fix my own rear door latches. One has been non-working for about a year (would have looked into fixing it sooner, but with my work going as well as it is and the "honey do, before honey don't list" I have put it off until the other quit working 2 days ago) and now the other side is not working either. I really like the ideas and pics that BigTexan99 has, but I thought of another, maybe stronger, fix that his wall anchors gave me. I'm gonna try metal rivets with the center "pin" taken out and crimp it onto the cable. May not work as planned right now, but I really appreciate the ideas and help these forums give us guys that try to fix our own problems when we think the oem "fixes" cost too darn much.
Reply With Quote
  #12  
Old 04-30-2014, 05:19 PM
Krochus Krochus is offline
Elder User
 
Join Date: Sep 2006
Location: Alma Arkansas
Posts: 791
Krochus has a good reputation on FTE.Krochus has a good reputation on FTE.Krochus has a good reputation on FTE.
Mine did the usual cable break where the upper latch cable broke off the retaining end where it's held into the door handle mechanism. Rather than drop $100 for a new cable I simply bolted an L bracket to the inside of the door in such a way that I could zip tie the broken actuator cable to it and thus prevent it from jumping free of the latch mechanism even though the end is still broken


I had to physically unbolt the upper door striker from the door frame to get mine open
__________________
Y2K f250 extended cab "base model"
7.3-zf6 php tuned, 6637 intake, muffler delete.
Reply With Quote
  #13  
Old 05-01-2014, 10:02 AM
countrycar's Avatar
countrycar countrycar is offline
Elder User
 
Join Date: Mar 2007
Location: Simi-Valley CA
Posts: 942
countrycar has a good reputation on FTE.countrycar has a good reputation on FTE.
Subscribed
__________________
99.5 F-250, 4x4,AT,with a few Mods. Carlos Briceno/ Aka Country
Reply With Quote
  #14  
Old 05-01-2014, 10:57 AM
eyyu eyyu is offline
Bricks & PSD
 
Join Date: Apr 2004
Location: STL MO
Posts: 377
eyyu is gaining momentum as a positive member of FTE.
Cheap Permenant FIX

instead of using the cable tie and plastic anchor thing, I used something called Woodepox. It's what one would use to fill holes on your wood parts. It's very strong (stronger than wood and plastic), easy to form into any shape you want to. If your door cable assys start giving your trouble, you might want to order some of this stuff, you will never regret it since there are houndreds of other uses for it around the house and the truck.

Look at the picture attched. I'm confident that it will outlast any new OEM parts! Hope that this will help someone. Eriwn
Attached Images
 
__________________
new baby: 99+ SC dually, Auto 4R11 4X2, 166,000, DP F6 and Infinity, 50c, AFE intake, A-pilar tri gauges, hardwired TC and EBPV switch,Hutch-Harpoon, FP sender
Towing: 2004 Forest River FlagStaff 8528BHSS 30' BunkHouse
Bobcat MT55: to move the 5th wheel around the driveway like nothing else! ask me how.
Dirty work truck: 95 F350 7.3 PSD RED crewcab, 3 underbed toolboxes. shim FPR, 140V IDM, 96 PCM
Reply With Quote
  #15  
Old 05-01-2014, 11:05 AM
fbh31118's Avatar
fbh31118 fbh31118 is offline
Senior User
 
Join Date: Apr 2011
Location: Michigan
Posts: 316
fbh31118 is gaining momentum as a positive member of FTE.fbh31118 is gaining momentum as a positive member of FTE.
I wish I had that latch to do over again so I could have taken pictures of the entire process. My door latch works great to this day, it was just my luck that the cables didn't break.

If someone needs one of those lower door latches worked on and want to send it to me I'll take some better pictures and update the thread on that lower latch.

http://www.ford-trucks.com/forums/10...tch-fixed.html
__________________
Built by Ford powered by INTERNATIONAL HARVESTER Chicago, Illinois.......please farm responsibly.
"Never argue with an idiot. They'll drag you down to there level then beat you with experience"
2002 Ford F-350 Superduty 7.3 Liter Navistar Diesel manual 4x4, 3.73 ratio, True Blue, Bone Stock
Reply With Quote
Old 05-01-2014, 11:05 AM
 
 
 
Reply

Go Back   Ford Truck Enthusiasts Forums > Diesel > 1999 - 2003 7.3L Power Stroke Diesel

Tags
2003, broken, cab, cable, cables, door, f150, f250, ford, latch, open, read, rear, super, supercab, top, truck

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
new pics for the scooby van scoobyvanjack Ranchero & 1961 - 1967 Econoline 5 10-31-2013 09:50 PM
DIY Bumper Grille '11 F150, Expanded steel ThirdsACharm Aftermarket Products 0 01-08-2012 02:05 PM
F350 TrailBlazer - Slide in camper on steroids! bigtexan99 1999 - 2003 7.3L Power Stroke Diesel 0 10-10-2011 05:46 PM
Installing Rear Shock help 78ford351m 1973 - 1979 F-100 & Larger F-Series Trucks 26 07-27-2011 10:38 PM
New Cab Installed Today, need some advice 78ford351m 1973 - 1979 F-100 & Larger F-Series Trucks 8 07-24-2011 02:25 PM



All times are GMT -5. The time now is 07:51 PM.


Powered by vBulletin® Version 3.8.7 AC1
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Advertising - Terms of Use - Privacy Statement - Jobs
This forum is owned and operated by Internet Brands, Inc., a Delaware corporation. It is not authorized or endorsed by the Ford Motor Company and is not affiliated with the Ford Motor Company or its related companies in any way. FordŽ is a registered trademark of the Ford Motor Company.

vbulletin Admin Backup