Mitch - glad to hear you found the problem. Door handles are fairly straight forward to replace but can rate high on the frustration factor because of the tight quarters going on in there. Don't know if you've done it before but here are a few tips from my experience.
The first thing in you way is the plastic shield that covers the top of the main mechanism and the linkage to the handle. If that shield is already missing from your car the good news is it's not in your way, the bad news anybody with a thin wire or coat hanger can get into your car. If the shield is there, it's the first thing you need to remove. If it's not try to find one and get it put back in. It's the last thing to reinstall before the door panel.
The second thing in your way is the main latch mechanism, no need to remove it just disconnect the linkage coming from the interior handle and remove the three screws that hold the mechanism and let it drop down. Moving that mechanism down will get you a lot more access to the bottom of the handle assembly.
Now to the rod from the main mechanism to the handle, it will probably need to be disconnected on both ends. Note if there is a clip on each end and it's orientation on the rod. Also this rod has a threaded adjustment on the bottom. If your handle used to work fine, the adjustment was probably fine, just don't go spinning the bottom end without reason.
With the rod out of the way, next on to the two nuts holding the handle. The one towards the front is fairly easy to get to but the rear one will certainly test your patience. I have found it easiest to raise up the handle as you loosen this back nut, there's less room for the nut and your wrench as the nut spins down the stud. Don't worry if either of the two studs come out of the handle with the nuts, I'm sure your new handle will come with new studs.
With the old handle out of the way, now is the perfect time to replace the old gasket and clean up the gunk that accumulates around the outer edge of the old handle.
Reassembly is pretty much the reverse order of how you took it apart. Don't over tighten the new handle from underneath as it will distort the housing and the flipper will stick on the way down. Secondly, before you reinstall the plastic shield or door panel. make sure the handles open the door properly, both inside and out. If the exterior handle seems to trigger the main mechanism but needs a little extra oomph to get the door open, lengthen the connecting rod mentioned above by rotating the connector down the rod, you won't need much.
Hope this helps, let us know if you have any issues.
|UPDATED|10/19/2015 2:06:39 PM (AZT)|/UPDATED|
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John Sigmund
valkman57@sbcglobal.net
NCRS Member 61302
NW NCRS Chapter Member
Duct tape is the new Black !!
The cosmoline they used in 1968 to keep things slippery is now pretty sticky. Clean up the culprit with a good solution and grease it well. Good for another 40+ moons.
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