Hello

Today it was warm enough to change my broken driver side door handle. So I took some pictures and may be this can go into the tech folder to help others down the road.

First things first you need to remove the inner door panel, please see this great link from JWA!

https://www.ford-trucks.com/forums/1...l-removal.html

Once the door panel is off you need to un-clip the clip holding the rod in place. After trying to un-clip by hand I tried a screw driver which did not work then the pick in the picture which worked perfect. The placement of the clip is not the best so you have to reach in.

You can now pull out the rod.



You can now drill out the rivets holding the handle on. Once the rivets are out you need to wiggle the handle and rod out as one piece, pull from the outside. This takes time so don't loose your cool!





Here is the old part with the new part. Cost was $74 with 13% tax, I live in Ontario.




The philips screw on the old door handle came out and possible could have been repaired but there was not much thread left so I put in the new part as it looks a bit beefier.

I inserted the new part with the the rod up from the outside and slowly wiggled the handle in place. Again this takes some time so be prepared to do it a few times until it goes in.

Now seeing how my 1/4 pop riveter has left me some how, don't lend your tools. I used 1/4-28 x 3/8 bolts with jam nuts on the end. After loosing 2 many trying to start the nut inside the door I reversed the bolts and started the nuts outside, which turned out to be super easy and leaves no sharp edges!



I will rivet once I get my riveter back, or buy a new one. Put the rod into the clip, put the cover on the clip and you are done! Test the door and put the inner panel back on.

Hope this helps a few people. Pictures taken from my Blackberry Passport.

 

Excellent contribution PST----thanks for taking the time to add these here. This repair can happen just about anytime so its good having a reference thread.

I'm curious if the OEM part is all metal like the one it replaced or more plastic?

 

The part is all plastic except for the screw, spring and rod.

The exterior of the handle is textured while the factory part is smooth!

 

maybe this should go in the Tech Folder ?

 

That would be a great idea---I was thinking the same along with one other recent post about higher level door trim panel removal. If we could get PST to create a new thread showing his steps and a write up too adding it to the Tech Folder would be highly useful.

I will add just FWIW the older handles for all doors tend to have more metal in them---for this reason alone I'll grab those in the scrap yards that don't show excessive wear or are ready to break. That's not necessarily a knock to the newer stuff----its much easier to find and a whole lot less hassle getting one in hand.

 

I can cut and paste!

 

I cut and paste PARTS.............LOL

 

What? No duct tape or JB Weld? Creativity is a good solution to some problems too!

 

The OEM handles are all plastic now... I just replaced the side cargo door handle ($70.00 as well.) and it was plastic as well.

A tip for getting a riveter big enough to put these in is a auto body shop. Local guy charged me like $5.00 to put mine in. LoL, the riveter he had was so big, they looked like bolt cutters... but worked perfectly and it looks great.

 

The things I have fixed at the track with duct tape , chicken wire , ty-raps and even a kotex would surprise you.
I only use JB at home.

 

But not the Kotex right?