Changed out the drivers side door latch assembly including the cable and handle mechanism as well as the door bolt that the latch secures the door to.

Outside of the trouble of getting the rods all hooked back up and the latch in the right position it went smoothly until we tried the exterior door handle. It does not open the door. I can watch the handle move the mechanism inside the door but it seems it isn't moving it enough to disengage the latch mechanism to release the door however the connecting rod is a simple install. It goes into the clip on the inside of the exterior handle easy enough and fit nicely in the grommet at the bottom of the latch mechanism with minimal difficulty. Why is it not making enough travel to disengage the latch? I compared the latches before installing and aside from the new spring they use in the replacement versions they seemed identical. Any clues would be appreciated.

Lazarev

 

Is it locked?
What year is your truck?

 

It wasn't locked when we tried it. We did toggle back and forth with the lock to see if it was interferring but that didn't solve anything. 1993 is the year.

 

What happens when the door is open and the latch is engaged? I've had trouble with that sort of thing when the door was sagging heavy on the latch bolt.

To align the latch bolt (the thing that sticks out in the door frame)........Put the bolt in just firmly enough to stay then close the door. Run your star-bit with extension from inside the door, through the hole in the door latch and loosen the bolt enough to let the weight of the door put it in the right position. Push the door in to match the body lines, then tighten the bolt down enough so it will stay in place. Open the door and give it a final tightening. It will line-up exactly where it needs to be. I recommend doing any door-to-frame alignment first, if that's needed.

 

Good advice and will keep that in mind however, when I shut the door it lines up perfectly. My issue happens when the door is open or shut.

 

So, I woke up last night with an "aha" moment. I wondered if the window guide track wasn't interfering with the rod. So, took the panel off loosened the guide track bolt and the handle operated fine. Tightened it back up and no bueno. When I was doing the switch out, I noticed that the new latch assembly had the plastic insert that the rod goes backwards to the assembly that was installed. So, I flipped it around and put the rod in as original. I didn't think anything of it as it was now just like the old one but by doing this the rod was moved closer to the window guide causing the interference. Sad thing is (I think) had I left the new one as I got it the rod would be flipped 180 and wouldn't line up with the hole and retaining clip in the handle. Daughter needed the truck for work so, I had to put it back together before going further. Very confused by this discrepancy. I need to get this door right before moving on the the passenger door.

I also found that the window molding sweeps need replacing but, can't change them as they need good door panels and mine are falling apart. Found a company called "Coverlay" who sells them Any opinion on them would be appreciated.

Lazarev