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Broke another door handle today. This makes the second one in a year and since I've owned the truck. I'm not really snappin on em, but I was already in a pissy mood this morning then the handle snapped off at the gas station and got flung across my cab. Thank god it didn't brake the window.
This is really getting annoying. And that's gotta be ONE reason why I love autozone. They STOCK these frickin things in the HELP section. Go figure that one.
Remove your plastic door panel and you will likely find that the thin sheet metal it's bolted to has sheared mostly or completely off. Weld/rivet/patch/whathaveyou it back into place and it'll be fine. When I was poor I used a huge glob of JB weld putty and forgot about it, no problems since.
You must not the only one because most of the trucks I see at pick-a-part have already had theirs scavenged. +1 on double checking the sheet metal that the lever mounts to. It's not really as thick as it should have been and can tear out.
I've went through 2, but that was in the winter when we had -30* weather. My uncle has broke his about 4-5 times now.
But I got real tired real fast from having to roll down the window to get out, so i just got some steel ones out of 80-86 ford truck, they bolted right up, and are very sturdy.
The other big reason people break the handles is because the cable gets loose, so you have to pull a little harder to open the door, thats how mine is right now.
I've broken 3 since I bought it in 2000. I even made one out of 1/8'x 3/4" flat stock, and broke that one next to the weld.
I have a new one to put in when I get a chance to study the door further.
Some on here have mentioned the metal flexing at the mount, I haven't seen it flex when working the lever with the panel off.
There's no cracks or rips etc.
So that leaves me thinking it's the cable itself. I have no idea if it's stretched or binding or whatever.
I have no idea how to lube the cable, so I guess a new one will have to be bought. I found one on Ebay for around 21.00. Is that a good price? Can they be had at an parts store?
Lithium Grease would be a fantastic lube, or Graphite in a can. There's -lots- of stuff that you can use. Hell if you could get Dielectric grease in there it'd be as cheap as anything and would work fantastic too since it won't dry up.
The door and handle hinge are in tact. No problem there.
Just took the door panel off and replaced it. You can almost BET that ANY AutoZone would have that door handle.
I just ripped it up to get out of the truck (pissy mood) and WHAM.. Snapped off and threw it across the cab. I'm gonna get another truck in the next two months anyway. Gonna sell this one and use it for the first payment to cut the interest.