I just broke (and replaced) the handle on the driver side door. My old 95' F-250 had this problem as well. I have to crank up on the handle several times to open the door. Then finally the handle breaks off. Is there something inside that gets stretched? Worn out? Dirty? How do I make it open like a new door again?
Trouble opening door from inside
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If you have the door panel off, check for cracks in the sheetmetal inner door where the handle assembly bolts to it. It's a fairly common problem. I had to weld in reinforcements on my 94. Cheers!
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174 Posts
Same thing happened to mine, I simply stuck as big a washer as I could jam in there in the mounting clip and slid it behind the cracked parts. Had to use a longer screw but it works. I gave the thing a good lubricating and am being careful not to yank on the handle any harder than I need to.
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9,218 Posts
I had this happen on a trip on the passenger door. I just picked up a can of WD40 and sprayed quite a bit up into the door handle mechanism and every thing has been fine for the last 4 years. Quite possibly some dirt got up inside it and jammed things up for me.
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65 Posts
I had the same problem on my '97 PSD. It happened on my drivers door, I eventually broke the plastic handle off trying to open my door. I went to a junkyard close to me and bought the chrome metal handles off the mid-80's f-series trucks. They are the same bolt pattern and won't break as easy. I put them on and blasted WD-40 on all the opening mechanisms and everything works great now.
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10 Posts
I broke the driver and passenger side off within about 9 months of each other. Just reinforce with metal by welding or placing under mounting area like Patrick mentioned. You'll notice a firmer feel when lifting handle to open door. I also used a dry Graphite lube only because I don't care for WD-40...drys out and gets gummy down here in the "dry heat".
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