Door Latch Problem
I've not looked at the latch mechanisms, but have used several Dorman aftermarket replacement door handles before, which seem to have held up at least as well as the GM ones that kept failing on me every 5 years or so. That's really my biggest gripe with my 1996 is that the driver's door handle (inside AND out) was made with what I call "pot metal", and it weakens and starts bending over time, and then the handle breaks or just doesn't pull far enough to pop the latch, and then you pull harder until it DOES break. That's the reason I've been into that drivers door so many times since 1996.
I recently saw a YT video about the weak points of these trucks. Door handles were one of them. I guess I’ve been lucky since this is the first encounter I’ve had on this truck.
One thing I noticed after I opened up the door was the factory grease after 30 years had coagulated into this sticky mass.
I’m certain this is what contributed to my internal failure. I used large quantities of carb cleaner on that area and relubed it with white grease.
There is a little post attached to the handle that fits in a slot on the latch. It popped out of the slot/hole.
I struggled for over an hour trying to get that post in place. Out of desperation I asked a couple of guys next door who are always wrenching on things to help. Between the 3 of us, we got it put back together. It works now, sorta.
One thing I noticed after I opened up the door was the factory grease after 30 years had coagulated into this sticky mass.
I’m certain this is what contributed to my internal failure. I used large quantities of carb cleaner on that area and relubed it with white grease.
There is a little post attached to the handle that fits in a slot on the latch. It popped out of the slot/hole.
I struggled for over an hour trying to get that post in place. Out of desperation I asked a couple of guys next door who are always wrenching on things to help. Between the 3 of us, we got it put back together. It works now, sorta.
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