Replaced door handle, door still wont open

Replaced door handle, door still wont open

Postby Tiny [OP] » April 2nd 2010, 12:08am

When I got my 2001 cargo the rear door latch was snapped off. I ordered a new handle from partsgeeks.com and it arrived yesterday. I went out today crawled in the back and pulled the rear interior panel off and started to fiddle with the latch till the door popped open. Quick easy fix unbolt old handle bolt on new one, close door. Try to open it... wont open, take key from pocket and unlock door to be sure its not just locked. Discover rear door lock doesn't match my key, use climb back inside and unlock rear door from interior hinge, and open door.


With the door open I took a screw driver to simulate striker pin and latch the door. Handle does actuate the rod but not as far as it needs to in order to unlatch the door. Am I missing an adjustment somewhere? Doe I need to try and straighten the rod just a bit to try and take up some of the slack for the handle, Did I somehow order the wrong part even though it all bolts up fine?
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Re: Replaced door handle, door still wont open

Postby 1992RS » April 2nd 2010, 1:41am

My first guess would be that a rod got bent somewhere and needs to be adjusted or replaced maybe some one on here has a pic that could guide you in the right direction
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Re: Replaced door handle, door still wont open

Postby Tiny [OP] » April 2nd 2010, 3:30am

1992RS wrote:My first guess would be that a rod got bent somewhere and needs to be adjusted or replaced maybe some one on here has a pic that could guide you in the right direction


Had thought about bending it but didn't want to until I got some advice on here.
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Re: Replaced door handle, door still wont open

Postby 1992RS » April 2nd 2010, 3:42am

SO, with the door panel off if you pull on the rod it opens the door easily?? but with the handle the rod just doesnt have enough travel?? if so I would say something is out of adjustement I.E. a bent bar or one that is not bent enough. or maybe the latch needs to be lubed have you tried lubing the latching mechanism I would try that first then if it doesnt work then try looking into other issues
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Re: Replaced door handle, door still wont open

Postby Tiny [OP] » April 2nd 2010, 4:23am

1992RS wrote:SO, with the door panel off if you pull on the rod it opens the door easily?? but with the handle the rod just doesnt have enough travel?? if so I would say something is out of adjustement I.E. a bent bar or one that is not bent enough. or maybe the latch needs to be lubed have you tried lubing the latching mechanism I would try that first then if it doesnt work then try looking into other issues


Latch moves like butter from the inside and the handle doesn't get bound or anything it just runs out of travel before the latch opens. gonna tweak the rod a lil straighter. I think that should solve that.
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Re: Replaced door handle, door still wont open

Postby 1992RS » April 2nd 2010, 4:49am

so wouldnt you need to bend the bar a lil more to increase the travel caused by the handle moving?
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Re: Replaced door handle, door still wont open

Postby Bread Van » April 8th 2010, 10:36pm

Do you have power locks. My power lock failed in the "locked" position, causing a similar problem. On the rear door ,the lock mechanism isn't real obvious. I had to stare at it a number of times before I saw the little piece that I could manually flip. I'm talking about the lower dutch door, barn doors may be different.
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Re: Replaced door handle, door still wont open

Postby zerotool » August 17th 2018, 4:00am

pulling the handle to the full travel and the door latch still will not click open is caused by a failed circlip and or bent linkage rod. So , you need a document clip in the gallery photos. You need a 3/4" size.Squeeze the handles on the clip and fit it around the rod. I used long pliers or long surgery tongs. That will take up the slack that causes the long travel when trying to open the door. the fix stays fixed. you also might need to straighten the bent rod. See my other post. Old post , new fix, for continuing problem........ :ty: :ty:
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Re: Replaced door handle, door still wont open

Postby Leeann_93 » August 17th 2018, 9:53pm

And this thread is over 8 years old.

ONE post is sufficient. You don't need to spam every thread you find.
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Fixing drivers door handle inside latch rods linkage

Postby zerotool » October 12th 2019, 1:13am

when the door clicks open only after the handle travels to the last 1/32" , then you need a 1/2" document clip and likely a zip plastic wire tie to bind the 2 linkage rods together to secure the latch rod into the nylon hole, to stop the popping out problem. Photo shows the document clip clipped onto the latch rod and the 2 parallel rods are held together by a zip tie (left rod behind webbing and right rod next to spring and not too tight). You can avoid buying and installing a new door handle. i cut out a larger hole with a Dremel Rotary tool to make servicing the linkages easy. When it gets hard to open the door, some people pull too hard on the door handle and bhttps://www.astrosafari.com/posting.ph ... p=1528650# :ty: break it.
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Re: Replaced door handle, door still wont open

Postby AstroWill » October 12th 2019, 8:52pm

That poor door.

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Re: Replaced door handle, door still wont open

Postby sixsix » October 14th 2019, 8:01pm

X2


Was someone holding a gun on you ... kept you from Removing The Inner Door Panel ?

Very interesting fix - when all you have are office supplies and a SAWZALL...

Maybe go with a new Latch Mechanism. Do they still make it?
Here's where I pulled our Driver's side Door apart, including Motor, Lock and Latch w/ all the Rods n' crap.
I pulled the Latch for fun, wondering how it worked. Everyone else was sluggish, slowing or stopped altogether.
https://www.astrosafari.com/viewtopic.p ... 4#p1479004



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