bison
Well-Known Member
I replaced dr side doorhandle on the new to the wife truck today.
Normally it's a bear to get to the lock and handle rods and clips even with the innerdoor panel removed(what by itself is a rotten job).
So i decided on a simple and easy solution to get to the lock lever rod.....drill a 1 1/8" hole in the side of the door next to the lock.
Just remove the outer doorpanel to get to the one bolt that hold the front side of the handle.If you happen to drop that little bolt in the door one can fish it up with a extendable rod magnet trough the louvre under the latch.
With both handle bolts removed i could tip the handle out and up far enough to push from underneath the tab in that holds lock to the handle and push the lock inside the door( don't worry,it can't disapear to the bottom)
Then remove the vent louvre under the latch and remove the 3 latch bolts and lower the latch inside the door trough the vent hole(it'll just hang there)
Now you can remove the handle incl the rod from the door.Note were the rod engages the latch.
bolt the latch back in place with one bolt so there is better access to loosen the lock clip from the rod and push the rod out of the way to the back a bit.
Put the clip back on the lock lever and push the lock in the new handle till the tab catches and attach the handle rod trough the clip in the handle
Now get a 1 1/8" hole drill and drill a hole in the door(see pic) top edge near flush with the slanted part and 1 1/2 to 1 5/8" on center from the door edge"
Deburr the hole with a file to prevent cuts on the fingers.
insert the new handle with the rod end in the rod hole in the latch
Remove the latch bolt again and lower the latch with one hand and tip the handle back in the door with the other to keep the rod engaged and raise the latch back in place with the bolts.
Bolt the handle to the door loosly and check if the handle rod is still were it is supposed to be by working the handle.
The lock rod can now be fished up with a screwdriver or a piece of wire and pushed on the lock lever trough that hole.
Button everything up and put a bandage over the hole,job done.The whole procedure should take less than 1 hr incl time for beer
One can replace just the lock if need be by just drilling that hole to remove the lever from the lock and using the key to push the lock in and slipping a tie on the lock to catch it.The lock can be extracted from the hole and a new one inserted. as i have done on my 98 a couple years ago
Normally it's a bear to get to the lock and handle rods and clips even with the innerdoor panel removed(what by itself is a rotten job).
So i decided on a simple and easy solution to get to the lock lever rod.....drill a 1 1/8" hole in the side of the door next to the lock.
Just remove the outer doorpanel to get to the one bolt that hold the front side of the handle.If you happen to drop that little bolt in the door one can fish it up with a extendable rod magnet trough the louvre under the latch.
With both handle bolts removed i could tip the handle out and up far enough to push from underneath the tab in that holds lock to the handle and push the lock inside the door( don't worry,it can't disapear to the bottom)
Then remove the vent louvre under the latch and remove the 3 latch bolts and lower the latch inside the door trough the vent hole(it'll just hang there)
Now you can remove the handle incl the rod from the door.Note were the rod engages the latch.
bolt the latch back in place with one bolt so there is better access to loosen the lock clip from the rod and push the rod out of the way to the back a bit.
Put the clip back on the lock lever and push the lock in the new handle till the tab catches and attach the handle rod trough the clip in the handle
Now get a 1 1/8" hole drill and drill a hole in the door(see pic) top edge near flush with the slanted part and 1 1/2 to 1 5/8" on center from the door edge"
Deburr the hole with a file to prevent cuts on the fingers.
insert the new handle with the rod end in the rod hole in the latch
Remove the latch bolt again and lower the latch with one hand and tip the handle back in the door with the other to keep the rod engaged and raise the latch back in place with the bolts.
Bolt the handle to the door loosly and check if the handle rod is still were it is supposed to be by working the handle.
The lock rod can now be fished up with a screwdriver or a piece of wire and pushed on the lock lever trough that hole.
Button everything up and put a bandage over the hole,job done.The whole procedure should take less than 1 hr incl time for beer
One can replace just the lock if need be by just drilling that hole to remove the lever from the lock and using the key to push the lock in and slipping a tie on the lock to catch it.The lock can be extracted from the hole and a new one inserted. as i have done on my 98 a couple years ago
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