Exterior Door Handle Linkage Connection Solution

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Dejure

Junior Member
Joined
Mar 3, 2025
Posts
12
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25
Location
Eastern Washington
First Name
Kelly
Truck Year
1978
Truck Model
C15
Engine Size
350
78 Door Linkage

A follow-up on the “Locked Out, And The Truck Is Running” saga I posted elsewhere:

Getting to the linkage tying the exterior door latch to the door latch mechanism was, initially, other than fun.

A bit of head scratching later, and I went and looked at my rod and tube collection. There, I found an aluminum rod about 5/16" in diameter. I had steel ones too, but grabbed this one for its ease of drilling.

I have a collection of rare earth magnets on one of the metal man-doors to the shop. Several, of differing sizes, have a counter sunk mounting hole. I used a small one, about 3/8" in diameter.

I grabbed a screw sized right to fit the magnet, without leaving any of the head above the magnet surface.

I found a bit just a smidgen smaller than the screw threads.

I mounted the rod in my drill press vice at a facsimile of 90 degrees by dropping it down the hole in the base, to allow bits to do their thing. Then drilled a hole deep enough for the screw.

Even if the screw didn’t go all the way down, a sloppy fit would have worked, for the tool I was making and its use.

This would make a holding device, for the retainer clip, and would allow me to reach back where my hand wouldn’t fit.

Next, I grabbed another rod I had. It was about 3/8" in diameter and already had a 90 bend.

This saved me from making one using a piece of 1/8" rod/wire with a 90", 1/2" to 3/4" long bend on one end. It would have a, roughly, 1/2" piece of scrap aluminum leavings at the metal bandsaw drilled and slipped over the bend and secured via a few whacks from a ball peen hammer.

This was to serve as a spacer, which would fit behind the linkage, after it was pulled into the hole of the bracket that would tie it to the door latch. With this in place, pushing wouldn’t push the rod back out of the hole, and I’d be able to push the retaining clip over the rod end and pull it down to lock into the groove.

I loosened the three latch mounting screws nearly a quarter inch.

I used a long screwdriver to manipulate the linkage to a position it would go through the bracket hole.

I used one of those grabbers that are on a long wire-would sleep and moved the linkage into the hole, from the back, instead of the front, but how images indicate they are mounted.

I put the spacer behind the linkage, holding it in place.

I put the retainer on the magnet and slipped it over the rod end.

Using the long screwdriver, I pushed the clip down and in place. The flap of the retainer slipped into the groove of the end of the linkage rod.

I removed the spacer, magnetic retainer clip holder, and tightened the latch screws.

The door operates fine. No binding, though images suggested it would come in from the opposite direction [for some unknown reason].


[headed out the door, will attach photos later].
 

Attachments

  • DoorLinkInstTool-1.jpg
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  • DoorLinkInstTool-2.jpg
    DoorLinkInstTool-2.jpg
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Last edited:

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