hi all,

my driver's side door handle snapped right at what appears to be a weld seam on the portion of the door handle that is curved and then attaches to the rod that pushes the door latch open when you pull the door handle up. I've got a donor handle and rod with the plastic piece that fits into the small hole/lever on the door latch inside the door, but I can't seem to be able to get the rod to fit because it's too long and the angle doesn't work after fiddling with it for an hour last night. 

I was wondering if anyone has done this before and if they found it necessary to remove the entire window sash and door latch in order to fit the rod into the proper hole.  Hope this makes sense. I don't have pics handy but can post shortly if needed. Thanks for any thoughts on this, I searched but didn't see anything addressing this specific issue.

Is the donor from the same side of the car? Can you swap the part from the old door handle to the new one?

I did this exact job last year. It is a royal PITA. It can be done, it requires some patience, preferably some small hands.

Some advice:

You need a ratcheting open end 10mm wrench.

It was hard getting the threads started. I pulled off the long bar that goes down the the door lock at attaches with plastic clips. It took me at least 1.5 hrs to figure it out. I may have posted about it. Let me check.

Good luck.....you can do it. Tip: sometimes it works to crazy glue the nut to your finger to allow you to maneuver your hand to the right spot without dropping it. Start the threading then pull your finger off.

 

 

 

 

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never seen an open ended ratcheting wrench, seems impossible.  Must be a typo, empty mini bar? 

just playing John!

Whelp, my bad.

https://www.lawsonproducts.com/lawson/Wrench-Open-End-Ratcheting-10mm/16414.lp?utm_source=google&utm_medium=cpc&adpos=1o1&scid=scplp16414&sc_intid=16414&gclid=EAIaIQobChMI9qDWpZKq4QIVxI2zCh3jbwksEAQYASABEgJccvD_BwE

Edited March 30, 20195 yr by siteunseen

The other end of the open end wrench has a ratchet

 

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I know you were kidding


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Donor is same side door from my previous 72 240 that has gone to z heaven but not before I stripped it bare.

 

was hesitant to break the plastic connectors but will consider that. I’m thinking of cutting the end off the rod so it will fit and maybe put a plastic washer after the existing “plastic screw thingy”. Will post pics later if interested.

6 hours ago, lking240 said:

I can't seem to be able to get the rod to fit because it's too long and the angle doesn't work after fiddling with it for an hour last night. 

I was wondering if anyone has done this before and if they found it necessary to remove the entire window sash and door latch in order to fit the rod into the proper hole.  Hope this makes sense. 

Kind of doesn't make sense, what you're trying to do.  I did like AV8 in my 76 and figured out what needs to go in first and getting the little nuts off the back of the handle, etc.  The rod just presses in to the bushings.  No need to break anything.  Can't tell what stage you're at, if you have the new handle in already or if you're trying to figure out how it works first.

A few pictures might help

pics attached, first shows the break in the handle, the second shows where the rod goes down past the connector to the door lever. The door lock does not function properly (the push rod on the door doesn't close/open the lock) nor does the key lock work well (it turns, but doesn't lock) but the inside pull lever works well, so I'm thinking I might want to dive in and try to rehab the entire system, both sides.

z door handle.pdf

on my 76 - 280 the drivers door handle broke just like yours and I moved it over to the passengers side and the the passengers side  to the drivers side.  Took about 2 hrs. to do, hardest part was putting the nuts back on.  Good luck.

As I recall, you have to thread the rod in as you put the handle into the door.

I recall you need to pop the plastic piece out of the handle in your first pic and then put to other end in the hole. Then you’ll be able to pop the rod back in the plastic piece.


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