I got all excited about this weekend. The Redhead and I were going to go to town on Skippy getting the little tweaks finished. Then The Blonde (the Wife, AKA The Boss) said Saturday was hair appointment day and Sunday was trip to her family day. Fail.

So I'll just have about 2 hours to spend with the kids on Sunday. Guess I'll try to get more done myself during the week.

To get ready I ordered some more toys.




A new upper latch for the left side. My truck has NO latches at all on the uppers.

http://i57.tinypic.com/35c3p0o.jpg




And for the right hand side (passenger side) a whole new linkage setup

http://i58.tinypic.com/fmi7bs.jpg




Finally some of those fancy dancy aluminum tips that don't break like banker's promises when you pull on the handle. I'll be installing these everywhere.


http://i62.tinypic.com/2ah75p3.jpg







They should all be here Saturday. Until then I'll be working on the dent more and the door locks. I'll be re-keying them because they don't seem to work with the ignition key, either that or they're full of dirt and frozen up. Either way they'll work in a minute :-drink

https://cimg8.ibsrv.net/gimg/www.for...ac56026661.jpg

LOL! Ain't that the truth!


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Nice job and great pics!!! As for the door locks, try to spray some WD-40 in the key hole while working key in and out so the fluid will git in the key hole then start turning the key to lock/unlock several times. That should work unless the tumbler was changed out then no dice.

I bet you could find another door for a good price vs trying to fix the one you have. When I got my truck from Alabama, I thought for sure that someone was going to call me and want half of their state back because it had so much Alabama dirt it.


I'm concerned about your injectors because of how your fuel system looked. Great work!

Just read through this whole thread, now I'm tired again, feeling lazy now after reading through this.....I probably should go back to bed and start over.

Nice job Glowplugger......

That's a good idea Scotttahoe! I tried lubing it up but no dice. I took the door apart yesterday and found out that the handles were replaced at some point and would never work. So I fixed that. Pics coming up!

Yeah, that bothered me too but he seems to run great aside from a belt/pulley squeak. I wouldn't hesitate to take him for a long trip. Is there a symptom to having gritty injectors that isn't readily obvious?

About the doors, I've never done any body work before but I was curious to see how well I could do it. Yesterday I massaged the big ding under the handle to a less pressed look. I don't want to drive around a big tub of Bondo though so I'll be working on it more today. I found some doors locally for $200 each but man, that's just too much money. And they're black so I'd have to paint them too. :(



Aww man! Sorry about that. Looking at your sig tells me you're not the lazy type. That's a lot of mods!





Tonight I'll post pics on the lock fixing, or "Re-keying your door locks for dummies on a budget!"


Stay tuned!

This is a great thred! Fun and somewhat informative. I think I'll pull up a chair over here by the beer fridge and watch some more. :-drink

Welcome aboard! Grab me an Angry Orchard while you're at it :-drink


I'm going to cross post this next bit into the SD forums for anyone with similar issues to find in the search engines so when you see it twice, well don't worry. it's on purpose :-X03





So.....I mentioned before that when I picked up Skippy I had an igno-second experience. An igno-second is that last second where you feel panic as you shut the car door, realizing your keys are still in the ignition.

In my case I realized I hadn't checked the door locks to see if they worked when I shut the locked door. Of course they did NOT work. That's why we were in the rain waiting for AAA to come rescue us forever :(.


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So here's the fix for that. The key would go into the lock, but wouldn't turn. The lock would pull up and down and the handle would open/unlock from inside, so nothing seemed wrong with that. Actually one of the locks was hard to push up and down, but that loosened up after a few pushes. I knew I'd have to pull the locks and see what the hangup was.


To remove the door lock you have to start with the inside panel. Actually you could just cut the door handle off but that wouldn't be as neat when I tried to put it back together.

First you grab the front of the door arm rest and just rip it up. It pops right off.

http://i59.tinypic.com/2h81qon.jpg





Next do the same for this portion up by the mirror.

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There's two little courtesy lights on the bottom of the door. Mine are missing, but you can pop them out with a screwdriver if you have them. Under that there's a little bolt. It's probably metric, but I used a 9/32 socket.

http://i58.tinypic.com/2lmuss2.jpg









There's another one in the handle, same size.

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The door handles were puzzling. I looked for a keeper on the back of them but they didn't have anything. Finally I figured out they had a cover on them that pops off and just twists out of the way. Use a flathead screwdriver on just the edge of it and the cover will pop loose.

http://i57.tinypic.com/6r7wa9.jpg

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Then inside there's a 7/32 star. Just insert and unscrew, then it pulls off with a little tug. The Redhead came home early from school to help so I let her take over here while I worked on the other side. Due to the dent things didn't line up right.

http://i57.tinypic.com/jjr3gi.jpg

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Then just ARRGH on the door panel, lifting up and it'll come free.

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There's a plastic shield thingy behind the panel. Peel it from the top corner down to the bottom where the edge cover (black) is screwed on. Be careful where the plastic hits the door lock plunger up by the window. Also be careful down by the edge cover, it'll tear there too.

http://i59.tinypic.com/2lw7tc7.jpg

http://i62.tinypic.com/optksk.jpg

Here's the Angry Orchard my friend. :-drink

With the barrier pulled back you should just be able to get to a 11mm bolt in the door here. Take it out.

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Then go all the way through the door through this hole with three small extensions or one large one. There's an 11mm nut on the back side of the handle that you can just barely see if you move the big black bar that you just unbolted from the bottom. You might have to push on it a bit to get it out of the way so you can see the nut.
BE CAREFUL NOT TO DROP THE NUT IN THE DOOR CAVITY!

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Now on the outside of the door there's a rubber plug you have to pull out.

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Under that plug is the final 11mm nut. Take it off too, taking care not to drop it in the door cavity.

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Now the door handle pulls away just a bit.

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There's two rods held on by plastic connectors inside the handle. The first one is just pressure pressed in a clip.

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You can pry it open with a good screwdriver but we used a pair of snap-ring pliers to press the sides open and slide the rod out.

http://i62.tinypic.com/2ih70xk.jpg









The second rod is a pain to get loose. You have to open the clip holding it on by the bottom of the clip, not the top. So go in through the side of the handle to make it easier. None of it is easy. :(
And watch yourself. That door metal will slice you right open.

http://i60.tinypic.com/2ypmfcy.jpg

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Once it's out the handle just falls off. Here's a picture of the rod we just freed. Why should you care? Because notice this dust ring mark on the rod. That's where the clamp was before you monkeyed with it. If you don't put it back in the exact same spot :-arrgh:-arrgh:-arrgh YOUR DOOR LOCKS WONT WORK AFTER THE DOOR IS CLOSED, EVEN THOUGH THEY TEST OUT OK WHEN OPEN!!! :-arrgh:-arrgh:-arrgh

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Now take a screwdriver and pop off the retaining ring thingy where the door lock is

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It just pops out after that. Notice that the lock has a bar that points to the bottom bolt in the handle. Gotta keep things oriented when you put 'em back in!

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Carry that little lock piece to your wife's favorite countertop, preferably one that stains easily. Use a screwdriver to pop off the surrounding aluminum or soft metal cover.

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It may take some prying. Go all around it prying bit by bit. Don't worry about bending it a little, you can bend it back when you put it back on. The thing to watch for is tearing. It will shear if you're not too careful. Then it pops off.

http://i61.tinypic.com/2d0xq9k.jpg

http://i60.tinypic.com/240x3ja.jpg

Flip the lock over and look where the key goes in. That's a little door you need to GENTLY pry out.

http://i61.tinypic.com/33fggeq.jpg
http://i58.tinypic.com/2w1wc5w.jpg









There's a fat little spring under there too. Take that out and set it someplace safe. Springs like to fly away.

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Flip the cylinder over again and look at the back. There's a keeper back there. Pry it off gently with a screwdriver. The thing it's attached to breaks EASILY. Be CAREFUL.

http://i58.tinypic.com/10ojwp0.jpg
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If you're using the old locks clean them up with alkee hall (rubbing alcohol).

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Pull off the bar that runs the locks and set it somewhere safe.

http://i60.tinypic.com/s17mzr.jpg










Put the cylinder down, face up and press. The surround should push down but go slowly. There's another spring and pin behind there.


http://i60.tinypic.com/2ag4spu.jpg
http://i60.tinypic.com/2922po3.jpg
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Here's a closeup of the pin with the spring behind it. Sometimes it pops out easily, other times it'll stay put pretty well. But now you know how it goes if it falls out.

http://i58.tinypic.com/v7y6ih.jpg









Back to your cylinder, clean it up a little with alcohol then we'll pull the pins out.

http://i58.tinypic.com/149rsig.jpg









The pins are really brass fins that are setup opposite each other. One pin on one side, flip it over and another pin on the other side, flip it again, and so on. You can push them from the opposite side if they're not wanting to pop up so you can grab them with a pair of pliers.

http://i57.tinypic.com/i20e1d.jpg









There's a spring on the side of each pin. Take that out too but don't bend it. It's sensitive.

http://i61.tinypic.com/msip29.jpg









Lay the first pin and spring down somewhere with a lot of room. You'll have six of these and you need room to lay them out like they came out so you can put them back in in the same place. Then flip the cylinder over and pull the next pin out, putting it opposite the first one after you clean it with alcohol too.

http://i59.tinypic.com/migr4i.jpg
http://i57.tinypic.com/2drci8l.jpg
http://i62.tinypic.com/358zyib.jpg





Keep on going for all 6 pins and springs, till they're all cleaned up. Clean up your cylinder too if you haven't done it already. Do the sleeve the cylinder goes back in too.

http://i59.tinypic.com/b6zwqv.jpg









Now put them all back in the same way they came out. And stick your key in the keyhole. Notice when you do that some of the pins are NOT flat to the cylinder? Those are the problem. They're stopping the lock from turning!

http://i60.tinypic.com/2m46p2b.jpg









Here you have two options. You can just take the ones out that are too high and toss them, leaving only a few pins to make your lock work. I don't like that idea so I fixed the pins. Take a file and run those tall pins down to flat. They're soft brass so they file down pretty easily. Be careful not to tear up your lock cylinder with the file!

http://i62.tinypic.com/2v9y97q.jpg

Once you get 'em filed down flat run your finger over them to make sure they're pretty close to smooth. The corners are the real important part. That's where the cylinder catches.

http://i60.tinypic.com/51c7q.jpg









If you're pretty sure you got it, stick the cylinder back in the sleeve and put the key in it. Then make sure it's not upside down. It'll sink in the sleeve farther when the cylinder's right. Does it turn smoothly? If not, file on it some more. Don't forget to check the bottom pins too!

http://i60.tinypic.com/2f03806.jpg









If it works, Good Job! :-jammin


Now flip it over and put the bar and keeper back on. If your pin and spring fell out, put those in first though. :-X21

http://i57.tinypic.com/344xyjr.jpg
http://i57.tinypic.com/4qk5d1.jpg









Flip it over again and put the spring in that goes under the little doorway.

http://i60.tinypic.com/2guy4as.jpg









Gently slip the doorway on again. It aligns where the pin for the door springs go in little slots in the cylinder. Don't force it!

http://i59.tinypic.com/2z9fvhy.jpg









Now for that stupid cover. It's weak metal so just grab a pair of pliers and press it back into shape. I bent mine a little more inward where it grabs the cylinder so it would hold tightly.

http://i60.tinypic.com/2yjrixf.jpg

http://i58.tinypic.com/ic4ms3.jpg









Then just press it on.

http://i57.tinypic.com/15htoh.jpg









Tada! Perfect!

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:-drink

After that clean up all the mess you left on the wife's counter and run back outside.

Slip the lock back in the handle with the bar pointing to the bottom bolt, "like it's supposed ta do"....



http://i58.tinypic.com/2lw86et.jpg









Slip the keeper back on

http://i57.tinypic.com/33043v7.jpg









And if you closed your doors, reach inside and PUSH DOWN on the plastic keeper that was tied to the bar in the handle, then pull the door open.

http://i58.tinypic.com/2vvrz7r.jpg









Set the handle assembly in the hole again.

http://i58.tinypic.com/157zpr8.jpg









Align the rod from the handle in the EXACT SAME POSITION AS IT CAME OUT in the plastic clamp, then go in the side like this and press it hard so it locks. If you can wiggle the door handle and it pops out, it wasn't clamped.

http://i62.tinypic.com/2jdgl7b.jpg









Snap the bottom crooked bar in the pressure clamp that looks like a lobster claw.

http://i60.tinypic.com/219e2e.jpg









Then get that 11mm socket out and put a nut in it. Slowly feed it through and tighten it up on the handle.

http://i57.tinypic.com/2j1lpv6.jpg









Next move the bar inside and feed the bottom nut through.

http://i57.tinypic.com/208fm6c.jpg









Now have someone sit inside OR leave the other door unlocked. Lock the door you're working on and close it. Does the key still work? If not, you probably have the rod from the door handle too high in the plastic clasp. Take it all out and do it again. If you have fat hands this can get really frustrating. :-hair

If it all works then put the black rubber plug in the hole on the outside of the door, then reach through the hole above this bolt toward the bottom and hold the backing steady whileyou put the bolt in.

http://i60.tinypic.com/250imhe.jpg









Almost there! Lift the panel up and press it toward the door so all the little hooks at the bottom and side catch. Keep an eye on the door lock button too because it has to poke up through.

http://i60.tinypic.com/2hpq0kl.jpg









Then put the window handle on and tighten it up with the 7/64 star bolt.

http://i59.tinypic.com/160x8jc.jpg









At this point The Redhead grabbed the window crank handle cover, flopping loosely against the panel. She asked, "Which way should the crank go? It kinda just flops around so I don't see how it works to....(here she flipped it around absently and it locked into place over the window crank and snapped)....OHHH! Its just covers the handle - HA HA HA!

I had to share. She thought the cover rolled the window down. Har har har!

http://i59.tinypic.com/2vnjejq.jpg










After you finish laughing, put the bottom bolt in where the courtesy light goes and pop your courtesy light back on.

http://i62.tinypic.com/14muq28.jpg









Finally slap that corner piece back on by the upper window and the armrest piece. Then close the door. Give your new lock another try. If it still works, squirt a little white grease or WD-40 in the keyhole and you're done!

http://i61.tinypic.com/r1jyb9.jpg
http://i62.tinypic.com/2yuwxu1.jpg

Hey Plugger,
Nice work and loving the pictures.


The squeaking belt may be your tensioner. Just replaced mine 2 days ago. had lost most of it's spring tension and belt was slipping.


Caution, by filing those wafers down in your lock you just made it so many different Ford keys can open your doors. Granted the doors on these trucks are not that hard for a crook to get into if they want.