Interior door handles keep breaking
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#35
I read on here sometime ago, that the inner door sheet metal flexes. So I got a piece of 3'x 1 1/4"x 1/4" thick flat stock and mounted it inside the door. It's right in line with the bottom door panel pins.
I drilled holes so the pins go through the flat stock. Then I temporarly bolted it in with those holes while I drilled 5- 1/4" holes to permanetly bolt the flat stock in with 5- 1/4"x 3/4" bolts, 10 fender washers and 5 nyloc nuts.
It really stiffened up the sheet metal and so far the inside door handle is still working. By now it would have broken. I know I've replaced that handle 3 times before.
I drilled holes so the pins go through the flat stock. Then I temporarly bolted it in with those holes while I drilled 5- 1/4" holes to permanetly bolt the flat stock in with 5- 1/4"x 3/4" bolts, 10 fender washers and 5 nyloc nuts.
It really stiffened up the sheet metal and so far the inside door handle is still working. By now it would have broken. I know I've replaced that handle 3 times before.
#38
#39
I ran into this problem with my 97 F250 HD. I went really cheap and used 4 inch zinc coated steel braces from Lowe's for about $1 each. Just used a hammer to bend and mold them to the right shape and presto. They arnt pretty but they work. Now I have a 94 f150 that Im getting ready to do it on again.
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#43
92-97 broken door handle fix
After breaking three plastic and one metal, (bolt on, previous generation door handles) I finally took the whole door mechanism apart and found the problem! And have had no problems since i fixed it. I removed the door handle and looked at the hinge point on the cable mount bracket and it was worn and ovaled and the hinge piece had actually worn a grove in the base plate on the mount, so the cable was not pulling as far as it should and i had metal to metal grinding and binding. Compare the drivers side and passenger side and its obvoius. I bought a new one on eBay ($24), i cleaned everything and re-lubed all the parts and It works as new.
#44
#45
Another probable cause is the rubber bumper pad that is secured to the hinged part goes missing. This lets the hinge overtravel and the first few degrees of pull are much too hard. If you look at another hinge on a door that is not giving you a problem I bet you see the rubber piece I am talking about.
I was able to put a small bolt into the hole with a nut securing it, the bolt head provided enough of a lift that the missing rubber pad provided.
I was able to put a small bolt into the hole with a nut securing it, the bolt head provided enough of a lift that the missing rubber pad provided.