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PLUS: installed new front calipers and pads. MINUS: rear door handle's broke

Posted By: off-roader

PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 01/26/14 05:35 AM

New front calipers went in without a hitch. Replaced the old pads as well then fully bled the front brake lines.

Unfortunately however the rear door handle broke and it's not opening from the inside.

Will have to remove the rear sleeping platform to access the rear door and pull the panel so I can open it. <img src="/forums/images/graemlins/frown.gif" alt="" /> <img src="/forums/images/graemlins/angry.gif" alt="" />
Posted By: plh

Re: PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 01/26/14 03:42 PM

Quote

Unfortunately however the rear door handle broke and it's not opening from the inside.

Will have to remove the rear sleeping platform to access the rear door and pull the panel so I can open it. <img src="/forums/images/graemlins/frown.gif" alt="" /> <img src="/forums/images/graemlins/angry.gif" alt="" />


The rear on my '92 broke last summer, so when I got the '93 I removed the door panel and lubed the mechanism with white lithium. Did an inspection and it looked like old plastic (21 yo), anyways, broke a couple mornings ago at 0 deg F, but not the finger that sticks into the mechanism, this time the handle portion under the outside cover just split apart.

Ordered this replacement:

http://www.amazon.com/MITSUBISHI-MR230032-MB669338-ORIGINAL-TAILGATE/dp/B00DKOKYMC

$56 shipped. Same one I ordered last summer for the '92.
Posted By: TOASTY

Re: PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 01/26/14 11:51 PM

I replaced mine 9 years ago and it lasted 7 years, when it broke again i rebuilt it out of steel. <img src="/forums/images/graemlins/smile.gif" alt="" />
Posted By: off-roader

Re: PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 01/27/14 03:41 AM

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I replaced mine 9 years ago and it lasted 7 years, when it broke again i rebuilt it out of steel. <img src="/forums/images/graemlins/smile.gif" alt="" />

Is it like the OEM unit but in steel? I'll buy if you're still making them...
<img src="/forums/images/graemlins/cheers.gif" alt="" />
Posted By: plh

Re: PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 01/27/14 01:18 PM

Quote
Quote
I replaced mine 9 years ago and it lasted 7 years, when it broke again i rebuilt it out of steel. <img src="/forums/images/graemlins/smile.gif" alt="" />

Is it like the OEM unit but in steel? I'll buy if you're still making them...
<img src="/forums/images/graemlins/cheers.gif" alt="" />


Steel - that is a super good idea!
Posted By: Struc

Re: PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 01/27/14 04:52 PM

Quote
Quote
I replaced mine 9 years ago and it lasted 7 years, when it broke again i rebuilt it out of steel. <img src="/forums/images/graemlins/smile.gif" alt="" />

Is it like the OEM unit but in steel? I'll buy if you're still making them...
<img src="/forums/images/graemlins/cheers.gif" alt="" />


Take any pictures?
Posted By: TOASTY

Re: PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 01/27/14 06:23 PM

No pics, if this is something you dudes want i'll come up with a way to mass produce. Give me a minute, what's the magic number i need to beat cost wise? I'm guessing i need to be competitive with the replacement plastic part. The main ingredient here are the sides of the handle, they are a specific shape. if i can get those cut out in a non time consuming way the rest is easy. Stay tuned.
Posted By: off-roader

Re: PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 02/02/14 04:33 AM

Paul, thanks again for the lead on that part on ebay. I got it on Friday after ordering it las Sunday! Not bad considering it came from FL and was shipped USPS!

Quote
No pics, if this is something you dudes want i'll come up with a way to mass produce. Give me a minute, what's the magic number i need to beat cost wise? I'm guessing i need to be competitive with the replacement plastic part. The main ingredient here are the sides of the handle, they are a specific shape. if i can get those cut out in a non time consuming way the rest is easy. Stay tuned.


Def still interested although I won't be needing it right away LOL...

With Michael's help I installed the replacement OEM handle today!

It was a bit of a challenge because I wasn't able to open the rear door at all since the rear latch was broken and my internal door latch was also not working. Plus my sleeping platform prevented me from removing the internal panels to access the door latch mechanism.

So what we did is open the door from the outside latch using an Allen wrench! As you can see in the pic below...
[Linked Image]
... the plastic latch mechanism pushes down on an internal metal latch (mike's left index finger is pressing on it). That metal latch actuates a mechanism that opens the door.

Here's how we used an Allen wrench to push down on that latch from outside the door...
[Linked Image]

Here's kinda what it would look like as you did it from the outside... Except you probably won't see mike concentrating so intently on the process <img src="/forums/images/graemlins/wink.gif" alt="" />
[Linked Image]

All in all, it only took a minute or so to get the door open once we figured out how to open it.

Then once opened, it was a simple R&R process to replace the broken door handle. <img src="/forums/images/graemlins/kewl.gif" alt="" />

In addition, I also removed the shocks from Carlos' rig since they're fresher than mine which have started to go out. I'll have to install them on a different day though when I have more time. <img src="/forums/images/graemlins/cyclops.gif" alt="" />

As usual, special thanks to Mike for helping me out and really doing the bulk of the work! <img src="/forums/images/graemlins/cheers.gif" alt="" /> <img src="/forums/images/graemlins/kewl.gif" alt="" />
Posted By: plh

Re: PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 02/02/14 03:41 PM

Mine arrived on yesterday (Saturday) going to install today. Sunny - but for sure no short sleeves. 8F (-13C) :-)
Posted By: off-roader

Re: PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 02/02/14 04:44 PM

Nothing like that balmy Great Lakes winter weather you always have <img src="/forums/images/graemlins/wink.gif" alt="" />
Hopefully you'll be doing this in a heated garage. <img src="/forums/images/graemlins/kewl.gif" alt="" />
Check ur PM's btw...
Posted By: plh

Re: PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 02/03/14 07:14 PM

Unfortunately no heated garage. Did the repair in the driveway, it was sunny at mid-day and a balmy 13F. All went smoothly. Will post a few photos later. BTW on the PM: Thanks for the offer, always appreciated.
Posted By: off-roader

Re: PLUS: installed new front calipers and pads. MINUS: rear door handle's broke - 02/03/14 07:19 PM

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Unfortunately no heated garage. Did the repair in the driveway, it was sunny at mid-day and a balmy 13F. All went smoothly. Will post a few photos later. BTW on the PM: Thanks for the offer, always appreciated.

Glad it went smoothly! <img src="/forums/images/graemlins/kewl.gif" alt="" />
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