Lousy Door Latches/Handles TransSport Fixed Cheap Way

1993 TransSport 3.8L

These door mechanisms are a poor quality design. I replaced the broken door handles (left and right) with low priced after market units. They broke again shortly thereafter. They broke because the door latch mechanisms inside the door are faulty and worn; people were pulling and forcing the handles past the limits because the latch was not actuating within the proper travel anymore.

Most all of the parts at the wreckers were in the same useless condition. The dealer wanted $250 a side for new latch mechanisms; $500 for 2 latch mechanisms!!

-I took the door panels off.
-I replaced the broken door handles again.
-I drilled the latch release lever; the one that push rod was intended to control. The drilled hole was the size which will accept a sturdy bicycle brake cable.
-Thread the bicycle cable through the drilled hole; a knot is tied in the cable to act as a stop. There might be some other way to attach the cable down there but drilling was what I thought of.
-I routed the cable up and out of the existing holes in the new door handle plates.
-I coiled the excess cable to make a loop, and black taped the loop up real good. You can instead, fashion a loop out of windshield washer hose or something if you like.
-Don't just pull the door open using the loop or it will wear out too soon; pull easy on the door handle, and then pull the loop. Throw a little gob a grease, if you like, where the cable rubs. The door latches work foolproof.

Some people think I'm nuts but I made $500 with a piece of bicycle brake cable, plus no more nasty handles and overpriced mechanisms to buy from the dealer.:screwy:

If this thread helps you, please click me my very first 'Thanked' :)

Hey, I'll give you a heads-up. In the past, I've done something similar on a different GM vehicle. The hole that the actuator rod was in, on the interior door handle, was broke at the hole. I had enough room to drill another hole. It was still working when I got rid of it.

Good job.

Hey, I'll give you a heads-up. In the past, I've done something similar on a different GM vehicle. The hole that the actuator rod was in, on the interior door handle, was broke at the hole. I had enough room to drill another hole. It was still working when I got rid of it.

Good job.
Thanks jdl. You have a gift of ingenuity.
Sometimes 'fixed' things are better than new; it sure can be satisfying to overcome manufacturer flaws; a small victory that brings great joy.
Did you see my recent thread "http://staticaf.com/vbulletin/images/icons/icon9.gif Emergency Brake Cable Replacement Troubles 1996 3/4Ton 4x4" ? http://www.automotiveforums.com/vbulletin/showthread.php?t=1122090
I could use some feedback about whether to shorten those springs or just slap it all together and hope for the best.

Thanks for my first 'Thanked':runaround:

[QUOTE=tinkering;7106958]1993 TransSport 3.8L

These door mechanisms are a poor quality design....

I totally agree and would go so far to say that the whole car is a poor execution of a great design. I love the design and engineering, just wished they had fabbed better parts.

I took my 1994 latch out and welded the hole and redrilled, its really soft metal, then welded a washer onto the push rod to more evenly distribute the force. Did that 10 years ago and its still working, albeit, it's not working like a Swiss watch.

[quote=tinkering;7106958]1993 TransSport 3.8L

These door mechanisms are a poor quality design....

I totally agree and would go so far to say that the whole car is a poor execution of a great design. I love the design and engineering, just wished they had fabbed better parts.

I took my 1994 latch out and welded the hole and redrilled, its really soft metal, then welded a washer onto the push rod to more evenly distribute the force. Did that 10 years ago and its still working, albeit, it's not working like a Swiss watch.

I'm started going over the whole car again trying to restore, and almost there but then trans started slipping today.....might just transfer the title to someone with a little more energy.

I like your description, "...a poor execution of a great design." They were a great vehicle in many ways though. They leave a lot of room for guys to execute our reverse engineering talent.

I tried washers down in there to try to extend the travel of the rod but wasn't getting any success so I reverted to my flintstone logic and bypassed all of that junk. It sounds like you nailed it. The dealer wanted $500.00 for two door mechanisms! LOL LOL... not! Over the years I have developed an attraction to the 'functionally fashionable' (my phrase). When the bicycle cable breaks, I will tie a new one in there, VOILA.

We had the tranny rebuilt maybe 10 years ago. I always wondered if it would last because of that incessant pump whine, just like it did before the rebuild. It has hung in there though, except for a couple of lousy slamming shifts after coming down from a high speed kickdown pass on the highway. I have a new modulator valve to put on there; that might be the problem, and it's easy to change.
If the rest of your TS is in good working order, maybe it is still feasible to find a reasonable tranny rebuild job, and keep it available to drive; consider how much some folks spend per month on leased vehicles.

I know exactly what you mean by transferring the title to someone with more energy; my son has voiced that he might like to take over. The trouble is at the moment the van has laid down for a rest. While I am away it developed a lifter clack that apparently got fairly loud. Maybe it just needs some extra attention; I was letting the routine maintenance slide. I will see how loud after I replace the starter which let them down but fortunately right in front of the house! There are other things to look over too before I evaluate if it is worth keeping it around anymore. I have so many other vehicles and other jobs beckoning my future attention. If it goes I will miss it. That fiberglass body is bulletproof. Who can complain with 400,000 km on that 3.8L; what a good motor they designed there. Too bad they stopped building them; maybe the quality was getting in the way of sales quantity.

I still want to get it back on it's feet even if it is to pass it on to someone else. I don't want to sell that thing but then again sometimes you have to face logistics. I came across a phrase the other day, that I got chuckle out of, "You can't polish a turd."

Thanks for the reply. Post your developments on the old girl; tranny/no tranny. It would be interesting to start a thread solely to discuss the subject of when it is time to let the old TransSport girl go (or not). :grinno:......:iceslolan......:icon16: