I have a door handle problem. There is an actuating rod that opens the door when you pull the handle. This rod is threaded and has a small fitting on one end that inserts into a hole through the handle. This fitting is sheathed in a plastic press-fit bushing which helps hold the fitting into the handle hole and allows for some flexiblity in the movement when the handle is actuated.

The hole on my door handle broke apparently the result of metal fatigue. I bought a replacement handle and am not having any trouble replacing the handle mechanism itself. My problem is with the actuating rod fitting. For the life of me I cannot figure out how to press the fitting/plastic bushing into the hole. It is a tremendously difficult fit. I've tried using WD40 to no avail and cannot seem to get a pair of pliers in there to do the job.

My question is this: is there any secret to connecting the rod to the door handle?

Thanks in advance.

 

I've replaced / changed / fixed mine repeated times... it should pop right in...?

Maybe use a pair of waterpump pliers / channel locks to kinda fa-naggle it in there with a bit of pressure while the handle and rod are out of the door... then install and hopefully you'll have better luck with the other end of the rod fitting easier.

 

the plastic fitting rotates!! press at a 90 degree horizontal angle against the open side of the plastic fitting, on the long part of the rod, the plastic fitting will rotate. The short part of the rod which is bent 90 degrees from the rod will drop out of the hole bushing. So easy to do, hard to explain.

No hand tools required. Only use your fingers!

 

maybe this will help...?
Not the clip to the handle, but all attach/look the same way (at least in my 80)

Stu Aull
80GS
Alaska

 

-pop empty clip into hole
-press rod tip into clip/hole
-pivot clip arm up and snap it onto the rod

Stu Aull
80GS
Alaska

 

there is a hole in the edge of the door.

I used a small screw driver and a hammer to seat mine.

snap in the plastic (without the rod)
get the rod started in the plastic,
pull up on the handle a little to line it up with the hole better
and tap it in (a third hand helps but two will do)

also FYI
I swapped driver/pass handles to save buying a new one. There is a hole on both ends of the handle

 

Clip is identical to the one holding the hood prop, except for size. Study that one.

 

Nice graphics 7aull

 

I finally had some time to get back to the door handle and got it working! What worked for me was removing the plastic bushing and inserting it into the handle first. Then I lined up the rod and it just snapped right in. I also beleive it worked as this time i work my lucky Mazda hat.

So thanks everyone - I really appreciated the assistance.

 

I think that IS the jist of what we were all trying to tell you to do!
Glad its sorted out. Annoying how such little things can ruin a day...

Stu Aull
80GS
Alaska