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Discussion Starter #1 (Edited)
1/8" thick by 2" wide or so strip of steel from any home/hardware store.


Remove the handle pin that the handle pivots on. I had to slightly grind down a peened over section to be able to pull it out. I used a dremel with a high speed cutter bit to get in there.
Long and skinny needle nose pliers and a pair of linesman pliers helped here.




Trace hook end onto steel. Making sure to also scribe hole for the trip rod.




Cut out the outline.



And drill out the hole for the trip rod. 11/32" I believe.



Cut off old plastic hook. I just hacked it off with a 1/8" cutoff wheel on my grinder. Precision wasn't a big deal.

You have to cut into the blocked off end of the handle so you can insert the new steel hook.




I decided to also have the pivot rod run through the new steel insert. Just trace the hole using the pick or an owl.



Then I installed the new insert, lined up the holes using the pivot rod to keep it in alignment, and drilled 2 more holes so I can put in some reinforcement pins.




I used a couple small nails I had laying around, and drilled the holes to fit. Then I used some plastic epoxy inside the handle and on the new insert for extra help.

Put it all back together, cut off all but 1/8" or so of the nails. Put the handle in a vice and crimped the nails down to hold everything in place. Make sure you only catch the nails..

Reassemble the handle, reinstall in to the door with new rivets..



And you should never have to deal with this $!##$^%@# door handle breaking again! (this was #2 for me!)

BTW, this little tool here has become invaluable for working inside these doors and quite a bit else on these cars.




Took about 45 minutes to do. I've gotten good at working inside the doors..
 

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um , what goes wrong w/ them??
 

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The little pin that acts as the hinge's pivot (it also keeps the handle secured in its place) rusts out. Mine did, but I used a small stainless steel machine screw to fix it.
 

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This hasn't happened to me thankfully, but I do have a problem where sometimes when I pull the outside handle, as I release, the door lock engages, you can see the lock post thing go down as you let it go. So sometimes I just need to grab something from the car, and when I go back, it's locked. Or if I working on audio stuff and open and close the doors a lot. Anyone have this problem? I'll probably start a new thread so I don't hijack this one, but if some has a quick and simple answer, I'd like to know. Maybe PM me or something.
 

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Discussion Starter #6

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Broken handle also

My driver side door handle has just started to break. It is off the hinge pin at the front . I can still use it for now.

Is there an easier fix for this? What parts would I need?
 

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ok what if say the outside handle is fine, but the inside handle sometimes doesnt wanna open the door?
 

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Pull the door panel and have a look to make sure the linking mechanisms are all tight, and go from there.
 

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ill do that tomorrow after work. its not so bad where i have to dukes of hazard getting out, just sometimes when i pull the handle i have to yank it like 3 times, and i really dont wanna break it haha
 

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I've also seen and had them break at the pivot due to idiots pulling the weight of the fing door by the handle only. Ever since my local idiot repair shop broke it and replaced it I lift the handle gently and grab the door by the lip behind the lock area. Opening the door this way will severly reduce the risk of it happening again, of course your still likely to have an idiot date or other idiot passenger yank on the handle while the car is locked or pull the whole door open by the handle but that is inevitable.
 

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Well mines a little late for this DIY..but def. a great idea for the future..My plastic peice where the pin goes through on the front side of the handle is broke. Nothing to attach the pin to. Gotta put a new handle on it. Does anyone make a aftermarket one or is Ford the only place to get a new one?
 

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From what I recall they are discontinued. You'll need to pull a good one from a same color car, or pull a good one in the wrong color and have it painted.
 

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Thats what I was told, but the localFord house said they could get one for me...I found me a donor car for more parts so I will prolly just snatch them off it..
 

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My passenger door handle just stopped working turns out its the same problem, where the rod attaches to the exterior handle decided to break....
 

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You mean the 96 & 97s are different from 95 back cars in this area?
Yes, I personally feel the 94/95 style is FAR SUPERIOR to the 96/97 style.

People like the 96/97 style because it's flatter/sleeker and painted to the body color.

I like the 94/95 style because they never break and they have little lights by the keyhole (nice, neat little touch).
 

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I like the 94/95 style because they never break and they have little lights by the keyhole (nice, neat little touch).
Not all of the 94/95's did it was part of the lighting package. There were also light-up ones for 96/97 but I haven't seen those for ages.
 
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