Driver's door handle broke...

Driver's door handle broke...

Postby SAFARIYAHL [OP] » August 3rd 2013, 6:21pm

I just picked this van up last weekend and the previous owner has installed new handles all around. The driver's door handle clicks when you pull it but it doesn't unlatch the door. I've pulled the door panel but I'm having trouble seeing up into the inner door to see how the handle egages with the latch. Does anyone have any good advice here for me? Any help is appreciated!
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Re: Driver's door handle broke...

Postby Jasen » August 4th 2013, 3:43am

welcome to a/s

the rod probably popped off. maybe they didn't get it snapped in or the plastic clip is wore out or broken.
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Re: Driver's door handle broke...

Postby ccookie66 » August 4th 2013, 4:02am

I'm gonna stalk this thread, because I have this same problem. My drivers door handle broke off. Its been like that for almost a year. I always have to crawl through the passenger door or leave the drivers window down enough to reach in and open it. I hear its a pain to fix the door handle though...
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Re: Driver's door handle broke...

Postby Big_kid » August 4th 2013, 4:59am

To replace the handle, drill a hole to access the top stud then put a push plug in the hole afterward. There's a thread with pics here... somewhere.
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Re: Driver's door handle broke...

Postby pacaron » August 18th 2013, 2:18am

Big_kid wrote:To replace the handle, drill a hole to access the top stud then put a push plug in the hole afterward. There's a thread with pics here... somewhere.


How big a hole?. Bigger than the wrench? Yeah, getting that upper hex nut (or is it the lower, I forget) It is a big pain in the bazoo. Humm, drill a hole. Where do you drill it.. edge of door or inside?
I'll try that. thanks,
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Re: Driver's door handle broke...

Postby Jasen » August 18th 2013, 4:12am

how i did mine, no power tools required https://www.astrosafari.com/viewtopic.php?f=11&t=6594
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Re: Driver's door handle broke...

Postby wayne228 » August 18th 2013, 10:01pm

I had to change my handle too. I found if you unscrew the latch unit from the door you can move (mussel) it just enough to get to the upper mount screw without drilling the door. Not easy but can be done, even with power locks. Go slow & resist the temptation to beat the door with a rock. Good luck
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Re: Driver's door handle broke...

Postby wayne228 » August 18th 2013, 10:03pm

forgot to mention I used a 1/4 inch ratchet. The 3/8 inch will not fit
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Re: Driver's door handle broke...

Postby Drummernaut » August 19th 2013, 6:54am

Well.... kind of long story here.

I just went through this crap last Thursday for three hours. I bought a new driver side door handle and installed it at the beginning of this year. It was a little stiff but it worked up until a few months ago until it became hard to pull. Last week it just stopped opening.

I could see through the access hole that the linkage was slipping out of the handle and the handle lever was impacting the window track(causing the stiffness). So I took it apart and fixed it so the linkage was tight with no lever impact and tested the latch with no problems. Right after I closed the door for a full test... it would not open!!!

I took it apart again and bent the linkage... no go!!

I found that the new handle was not pulling the latch lever down far enough. It was only a millimeter difference but enough for the damn latch not to release.

I did not want to try and bend the tab on the handle because it was fragile. I took the latch out and added two small washers on the top end of the handle linkage where it connects to the latch. Problem fixed finally!!! Door opens smooth and easy.

I will have to do the passenger door because it was replaced last year and it catches once in a while whenever I do use it.

You will need a 10mm for the handle nuts. Wayne is right, the door latch is easy to loosen and move to the side(mussel) or remove.

I should have taken pictures!! I will when I do the passenger.
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Re: Driver's door handle broke...

Postby Drummernaut » August 19th 2013, 8:33am

Found a good youtube on what I was dealing with. The part I put the two small washers on starts at 3:12.

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Re: Driver's door handle broke...

Postby SAFARIYAHL [OP] » September 13th 2013, 11:06pm

Wow, thanks a ton for the responses! Sorry it took me a while to hop back on here. Business has been extremely hectic. Hectic enough that I'm just now getting around to fixing this issue this weekend so I really appreciate the responses. Yes, I've been dealing with this headache for a month...
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