1995 Ford F150 XL Regular Cab

After shutting off the engine and trying to open the door to get out of the truck, the door handle tried to slide out of the opening and I couldn't get it to open the door. Had to roll down the window, reach out, and open the door from the outside.

Opened the driver's side interior door panel today thinking that the handle had broken or cable broken, etc. Instead, it appears as though the handle base/spring plate has burst through the sheet metal so the handle is no longer anchored into the door.

I took some photos. Is this something that might be able to be welded? Maybe weld the bottom plate of the door handle mechanism to the blue sheet metal of the door? Anyone have any ideas how to fix or rig this back up? Rolling down the window and reaching out to open the door from the outside all day long sucks....and embarrassing

 

Yeah that's a pretty common problem. I've seen people fix it by putting a large washer on the other side and bolting it down. Friend welded his handle to the door but I'm not sure how that worked out for him.

 

Fender washer. Or just a piece of metal with a hole drilled. I'd put something like PL premium glue to keep the metal or washer from rattling later.

 

So just put a washer under the busted hole and then bolt the handle mechanism plate to the metal and washer?

Is there a self-tapping bolt or washer that I can use to attach to the plate? I don't see where I can reach under the sheet metal to hold the washer and nut in place?

 

Take the plastic off. You can reach down from above and hold a nut while you tighten the bolt.

 

Ditto on Fender washers and bolts. This is how I have repaired several door like situations to this one.

 

It can be welded, but burns through easily and weakens the sheet metal. Fender washer has worked on all 4 doors on both of my 150's.

 

I had the same issue on my 94 xlt. I cut a piece of a retired cutting board from a restaurant and used it as a backing behind the metal plate that the screws had torn out of. The high quality restaurant quality ones are made of some pretty seriously tough material that will never corrode like metal or rot or split like wood. A couple of self tappers through the original holes and I don't expect any more problems.
I considered welding but was also concerned about burning through and weakening the whole mount, or leaving slag that would interfere with the handles movement. Large rivets and washers would also work, but I had all this expensive material and nothing to do with it. It cut easy to shape with a scroll saw and I expect it last as long the truck.

 

Awesome! Thanks very much, guys! I went with the washer idea as it was the quickest, easiest and cheapest route. Went to The Home Depot and picked up an assortment of fender washers to make sure the handle mechanism bolt would fit just right. Washer model AJC fit almost perfectly with the bolt and little locking clip. I had to clamp the edge of the washer in a pair of channel locks and bend it back and forth until it tore a small notch out of the washer so the locking clip and the washer hole matched 100%. After I did that, I re-positioned the handle mechanism onto the door sheet metal, held the locking clip and washer under it, placed the bolt through the mechanism and used my little 1/2" drive ratchet with a 8mm socket and snugged it right up! Viola! Done! Went ahead and cleaned up the mechanism a bit, WD40'd around the area, replaced the door panel and it seems to work as good as new.

Quick and easy repair with the help of you forum members and a $0.32 cent washer! Not a bad deal. And no more rolling down the window and having to reach outside the truck and open from the outside!!!

Thanks again, guys!

 

All of the above suggestions about backing plates and washers are good. Also while you are on it scrub/spray that spring and moving mechanism with PB blaster and it really loosens it up and makes it easier to function/puts less pressure on that plate.

I learned the hard way.