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Re: 1997 cheap door handles?
I was going through the same thing a while back. I was breaking a handle a month. A couple times, new ones would break in a couple days. I installed a new metal one for an 86 and it broke in about a month also! The metal ones are just made of cheap pot metal.
I opened up the door panel and found that the previous owner had already welded the sheet metal section that brakes. My problem was that the cable is stretched, causing me to pull the door handle to its maximum travel to get the door to open.
What I did was bend the little tab that the end of the cable housing attaches to at the door handle side, away from the cable, affectively shortening the amount of cable travel required to open the door. It is kind of hard to explain but once you get in there, you will understand what I mean.
A better option might be to replace the cable assembly but I have not broken another plastic door handle in about a year now.
Hope this helps,
Invader
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Invader
97 F250 XLT SuperCab LB E4OD
Mod's: Tony Wildman 4 page chip, Stealth HPOP, Beans fuel system, JoeServo high voltage IDM, Swamps 175/173 injectors, Hypermax H2E turbo and inter-cooler, open element air filter, Down pipe, open exhaust, exiting in front of rear wheel, with dynomax bullet race muffler. Home made, dual stage, Propane system, ATS TripleLoc billet steel Torque converter. Imperial Shift Kit, BD PressureLok. Mag-Hytec tranny pan and rear cover, ARB air locker in the rear. Cervinis Fiberglass ram air hood ,(part # 112). 4" Superlift lift kit, Air lift air bags with Smart air auto leveling system in the rear, Full instrumentation, Grant steering wheel, on board air system. Putco skins stainless bed rail/tailgate covers. Stainless Nerf bars. Billet front grill and clear lenses all the way around.
My Truck Pic's
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