Exterior Door Handle - Replaced - will not work

Exterior Door Handle - Replaced - will not work

Postby tj-95gmcsafaritom [OP] » July 16th 2009, 2:19pm

I replaced the Driver's side exterior door handle, reconnected the linkage, but the door will not open from the outside.

As far as I can tell, everything seems to be installed correctly. The linkage does not seem to be pulled down far enough to trigger the lock mechanism.

If I reach in there with my hand or a pair of needle nose pliers, I can pull the linkage down and trigger the mechanism and it works fine.

Is there any way to adjust this linkage to shorten it, or to lengthen the pull travel so that it works?

Thanks

TJ
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Re: Exterior Door Handle - Replaced - will not work

Postby rev_les » July 17th 2009, 1:38am

it's more than likely hung up on the doorskin on the inside. loosen the nuts, pull the handle like you're opening it, and re-tighten them. Mine did the same thing the first time I replaced one.
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Re: Exterior Door Handle - Replaced - will not work

Postby tj-95gmcsafaritom [OP] » July 17th 2009, 4:33am

Hi rev_les,

Thanks for the reply.

The linkage is not hung up on anything. I can see it move when the handle moves.
The cam on the handle just does not seem to move the linkage down far enough to
trigger the lock mechanism to open.

I need to know if there is some way of adjusting or shortening the link that goes from
the door handle to the lock mechanism.

TJ
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Re: Exterior Door Handle - Replaced - will not work

Postby astro355 » July 17th 2009, 6:48pm

The way the latch is right now, if you closed the door, would it latch? Try using a screwdriver and see if the latch will grab the screwdriver as it would grab the bar on the door well of your van.
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Re: Exterior Door Handle - Replaced - will not work

Postby rev_les » July 19th 2009, 1:14am

Sorry, I misread the problem, I was thinking the exterior handle itself wouldn't move. :whistle:
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Re: Exterior Door Handle - Replaced - will not work

Postby interestingfellow » July 20th 2009, 5:31am

I just swapped out some doors (and their guts) and found that the littlest differences made huge differences. For example, there were some bends in the rods that had unbent just a little over time, to make the lock hard to work. So, I re-bent them, and lubed up the lock mechs and linkages, and viola! working how they should. Might be worth a try.

Good luck.
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Re: Exterior Door Handle - Replaced - will not work

Postby RootsMan » June 26th 2013, 12:41pm

Were you able to resolve the problem?

I'm having the same issue on a 2003 Chevy Astro, with a new driver-side handle.
The inside handle opens the door fine.
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Re: Exterior Door Handle - Replaced - will not work

Postby RECox286 » June 26th 2013, 1:06pm

From what I can gather there are 2 different styles of handle. Old and new designs. I had the same problem with one of

my door handles, install new replacement handle and no joy, try an older one and worked just like brand new. You may

have sort of the same problem. I wouldn't discount it...

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Re: Exterior Door Handle - Replaced - will not work

Postby valley ranch » June 30th 2013, 4:56am

2000 Astro, The passenger side handle just broke. Had to replace both sides. Had no problem replacing the handles on the safari, bought them on Ebay, now hearing about new handles that don't work makes me wonder.
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Re: Exterior Door Handle - Replaced - will not work

Postby chevymaherchevymaher is online! » June 30th 2013, 7:36am

valley ranch wrote:2000 Astro, The passenger side handle just broke. Had to replace both sides. Had no problem replacing the handles on the safari, bought them on Ebay, now hearing about new handles that don't work makes me wonder.
Rich

There are 3 types being sold on E bay. A plastic one. And 2 metal types. One is a s good as factory. I bought mine there. Best working handle on the van.
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Re: Exterior Door Handle - Replaced - will not work

Postby swharris » September 30th 2013, 4:14am

I know this thread is very old, but maybe my experience will help others.

The problem the OP was experiencing was more than likely the part of the handle bracket that the rod bracket is attached to was just about to break. The pot metal tends to bend significantly before it finally cracks.

I just finished replacing both sides. One had completely cracked and bent back enough so that the rod would not actuate the lock mechanism. Also, the return spring was broken so the handle was sloppy and not holding tight against the door. The other door's handle had not cracked/broken, but was sure to fail soon. It's bracket was significantly bent backwards and just barely actuating the lock mechanism. I suspect this is the condition the OP was experiencing.

I replaced both with aftermarket METAL ones from some on line supplier(sorry I don't know who). Good quality, if not GM OEM. The only issue I ran into was that the small plastic actuating rod clip had to be slightly modified so that it would snap onto the rod. It had inward facing barbs on it that made the clip too small to fit on the rod. After a long extremely frustrating battle of finger killing fiddling, I gave up and cut the barbs off the inside of the clip with a straight razor blade . Worked like a charm and still snapped onto the rod to keep it from coming off.

This can be a very fiddly and frustrating job, but just go slow and replace both handles. You'll be shocked at how good the door opens once you do. :-)
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Re: Exterior Door Handle - Replaced - will not work

Postby Sailing_Faith » September 30th 2013, 7:49am

.... After a long extremely frustrating battle of finger killing fiddling, I gave up and cut the barbs off the inside of the clip with a straight razor blade . Worked like a charm and still snapped onto the rod to keep it from coming off. ....


Hope it holds together for you like that.

For future reference, those clips have to be installed into the hole BEFORE the rod is inserted. The little barbs you cut off go in first, then when you click the rod into the hole, the barbs keep the clip from coming out of the hole.
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Re: Exterior Door Handle - Replaced - will not work

Postby Sailing_Faith » September 30th 2013, 7:52am

Similar clips,

image.jpg
The clip goes into the hole in the handle, and then the rod goes into the clip and is held in place.
image.jpg (5.82 KiB) Viewed 1831 times


image.jpg
Another random picture to illustrate...
image.jpg (6.52 KiB) Viewed 1829 times
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Re: Exterior Door Handle - Replaced - will not work

Postby swharris » October 9th 2013, 10:22pm

Sailing_Faith wrote:Similar clips,
image.jpg


The clips on mine are different. They had a double barb. I just removed the one that was not letting the rod clip in. As they are now, they are very tightly clipped in. I highly doubt that they will pop out. It's been two weeks of use and they are solid as a rock. Nice to not have flopping door handles.

Just re read your post. You missunderstood my comment about the barbs. I did not trim the barbs that keep the clip in the hole, I trimmed the barbs that were on the part the ROD snapped into. On the style handle I had, there were two layers of "barbs" inward facing on the "rod" portion of the plastic clip.

While different, you can see on this Lexus clip how the "c's" of the rod clip have a bit of an inner barb. The one on the aftermarket Astro handle had barbs that literally met in the middle. No matter how hard you pressed the "c" would not open up. I just slightly trimmed the barbs to allow the rod to snap into place. Still plenty of clip left to keep the rod engaged in the clip.
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Re: Exterior Door Handle - Replaced - will not work

Postby zerotool » August 17th 2018, 4:14am

See my post about circlip failure. you might also need to straighten the rod. :ty: Open clip by pinching the clip handles with long pliers and fit the clip around the rod. that takes up the slack and the door will open. no long travel to end of pull. 3/4" office supply store clip. and it stays fixed. also you may need to unbend the rod.
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Re: Exterior Door Handle - Replaced - will not work

Postby Astrofarian » August 17th 2018, 4:26am

Good info never goes out of style but you DO realize that the last post in this thread is almost 5 years old? The original thread was started over 9 years ago. Just say'nnn….
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Re: Exterior Door Handle - Replaced - will not work

Postby zerotool » August 17th 2018, 4:35am

Into the future with the door handle FIX. Down the road , someone will need it ................................................
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