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My interior door handle kept breaking and after reading an older thread took some advice and took it to the dealership and had them replace the cable/handle. It was absurdly expensive and the dealership's service was appalling, and in the end they let me know that it would still be a problem and to only expect it to work for about 6 months. 6 months came and snap went the handle. I'll summarize what I found for advice on the older thread:
Stop yanking the handle so hard! - Thanks but after breaking it the first time I have treated it like fine china and it keeps breaking.
Buy an 80-86 metal handle - this is then countered by other posters who say it's just chrome plated pot metal and will still break or worse, rip the door apart.
Replace the cable assembly with a rod assembly from 80-86 junkyard specimens. - Sounds promising but again someone countered, saying they had tried this and it still broke.
And, "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 temporarily bolted it in with those holes while I drilled 5- 1/4" holes to permanently 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." - This sounds resourceful.
Anything else I missed? Is anyone super proud of their fix job that has lasted years?
My 94 F-250 had this problem... I saw that weak sheet metal when I took the door apart, and I think I might've reinforced it but don't remember how, if at all. Then for the plastic handle itself, which snapped clean off, I just took and polished up a 5/8" hitch receiver pin, and welded it to the metal bracket where the plastic handle used to bolt to. Once the door panel was back on, it looked just like it was supposed to be there. Lubed the cable and latch mechanism and never had a problem ever again, it was working fine when I sold the truck. I did plan on doing the other side to match but never got around to it.
In my experience, checking the door for cracks or rips in the metal where the handle assembly is mounted, and check the cable for stretching.
Afterwards, lube the mortal p!ss out of the cable, and replace the handle with the 80-86 metal ones.
Again, as you said, dont try to lift the entire truck by the door handle.
agreed, I put the metal ones in my truck (no my plastic ones were fine, but im proactive on this stuff) and I have no issues, had to tighten down the pass side tho as it was loose, but thats because the place I had it done at didn't tighten it all the way proper.
I have yet to get the panel off to inspect my cables but I plan on doing that once I get the engine resolved, and lube the mortal p!$$ out of the cable, and if able rig in a pully system (cable guides) to keep the cables where they should be, also going to reinforce any needed parts.
I've sold literally hundreds of those door handles over the years...
It's a Ford part # E7TZ-1522601-A, and no, I didn't look that up-I still know it off the top of my head!
The ironic thing is, I've owned a '93, '95, '96, & '97, and I have NEVER broke a handle on one of my personal trucks!!
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