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Power Strokes 1994-1997 Upgrades and Aftermarket Upgrading or adding OEM or aftermarket equipment to your 1994-1997 Ford F-Series with Power Stroke engine.

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Old 01-17-2013, 11:38 AM   #1 (permalink)
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Broken door handle fix

I made new interior door handle out of 1/16 flat plat and 3/8 rod stock to fix my ever breaking ones. This upgrade should never break.
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Broken door handle fix-2013-01-17-door-handle-1.jpg   Broken door handle fix-2013-01-17-door-handle-2.jpg  
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Old 01-17-2013, 01:42 PM   #2 (permalink)
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1991 and older are metal and fit and dont brake
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Old 01-17-2013, 02:47 PM   #3 (permalink)
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1991 and older are metal and fit and dont brake
Good to know but unfortunately it looks like all replacements are plastic that I can see - checked both LMC and rockauto
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Old 01-20-2013, 09:52 PM   #4 (permalink)
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I replaced mine with one from Napa and it broke again in just a couple weeks. I got one from Ford, which really wasn't that much more than the Napa one and that held up a lot better. Then I started having some issues that I had to yank on the handle a little extra to open the door so I figured the cable was getting stretched out, which was probably the entire problem to begin with, so I got that kit from Ford too because I couldn't find anyone else that offered the complete kit more than just the cable. You have to tear the whole assembly out of the door anyway so I was happy to replace the whole thing.
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Old 01-20-2013, 10:15 PM   #5 (permalink)
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Those are nice looking. My only problem with building something that is stronger than the stock equipment is that you will eventually break the next weak link in the system. It turns into a domino effect until you get to the end of the loop.
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Old 01-21-2013, 10:04 AM   #6 (permalink)
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You can find on-line a pair of the metal chrome handles for $14.99 for a pair! If you keep the cables lubed and adjusted, these metal ones will last forever. And look better too !
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Old 01-21-2013, 05:04 PM   #7 (permalink)
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You can find on-line a pair of the metal chrome handles for $14.99 for a pair! If you keep the cables lubed and adjusted, these metal ones will last forever. And look better too !
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Old 01-21-2013, 09:12 PM   #8 (permalink)
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Ebay.....

Ford Bronco Pickup Front Inside Door Handle Chrome Pair | eBay
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Old 01-22-2013, 06:49 AM   #9 (permalink)
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thanks
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Old 01-22-2013, 05:55 PM   #10 (permalink)
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Looks positively Amish.... (and that's meant as a compliment; they're remarkable craftspeople....)

A stronger handle in this application is like a higher-capacity fuse to replace a blown one. Suppresses the symptoms temporarily, masks the cause. And as mentioned above, may just lead to more damage down the road.

If you have to pull hard enough to damage even a plastic handle, there's a problem elsewhere. The cable is stretched, the metal on the mounting/hinge point is fatigued, the latch and striker aren't aligned properly and are creating too much resistance, something like that.
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Old 02-03-2013, 09:53 PM   #11 (permalink)
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There is a little rubber button bumper thing that the handle rests against. If that's missing it can cause the handle to pull very hard. Doesn't seem like that would matter much but it does.
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Old 02-03-2013, 10:22 PM   #12 (permalink)
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I had to take door panel off to put new speakers in so I oiled everything up and door is working even better now. I will probably make two more door handles for the passenger side of the truck to match.
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Old 02-05-2013, 02:38 PM   #13 (permalink)
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I replaced mine with another plastic handle and when that broke, I went to the chrome handle. Got it from a local parts store. They are from the 90-92 trucks. I also keep the linkage lubed to keep me from having to use more force than needed on the door handle.
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Old 02-05-2013, 04:21 PM   #14 (permalink)
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Just ordered a pair of these, thanks!
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Old 03-02-2013, 04:36 PM   #15 (permalink)
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I have replaced mine 3 times in 6 years, the last time the sheet metal was torn and broken as well. I used the liquid metal playdo stuff to rebuild the area and haven't had trouble since and that was 7 years ago
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