Fixing the Cargo Door
Jan. 21st, 2023 05:45 pm![[personal profile]](https://www.dreamwidth.org/img/silk/identity/user.png){kind=small}
kevin_standleeAs I mentioned a couple of weeks ago, the handle to the rear cargo door on the Astro broke. We ordered a replacement door handle online. I could not find OEM parts, so we had to go with an aftermarket part that claimed to be for the Astro/Safari vans of this period. The new part arrived a few days ago, and with the storms having subsided for the next few days, Lisa decided to take on the replacement today. It was cold (around -5°C) but there was no wind, and the sun was shining on us, so we tackled the fix. Lisa did the work. I just held the door and passed tools to her when needed.
This was the second time we've had to replace this part, and for the same reason: the pot-metal handle has a weak point and breaks. This time, though, Lisa knew where to start.
There is an insulation panel in the rear door that also holds the rear speaker for the sound system. It doesn't really appear to be meant to be removed, but you have to remove it in order to get at this access point in the rear cargo door.
Once she had the panel off, it was relatively easy for Lisa to reach inside and pull the cable that releases the rear door latch, allowing us to open the rear door. Lisa then put the insulation panel back as best she could.
Once we had the door open, Lisa tripped the latch so that if we accidentally let go of the door, it wouldn't lock shut again. This the door handle access panel, which is relatively easy to remove once you have the door open, but is completely inaccessible when the door is closed.
Well, there's your problem: This bit of broken metal is what broke off the handle. You can see where it engages with the cable that actuates the latch.
Here Lisa is holding the new rear door handle with the old one at right. She is also holding the bit that snapped off the handle up to the broken handle so you can see where it broke away.
It should have been easy to attach the new handle to the latch release cable and then reinstall the handle in this space on the outside of the door. But the aftermarket replacement did not quite fit, and it took Lisa 30 minutes of carefully bending things (without breaking them) to make it actually work.
That release cable should be straight, but if hooked up that way, would not cause the rear door latch to release when we pulled on the door handle. Lisa did manage to make sufficient modifications that it started working.
After testing it multiple times until she was satisfied that it would work, and confirming that we could indeed lock and unlock the rear door, Lisa sprayed some Liquid Wrench lubricant into the assembly, put the access cover back on, and closed the rear cargo door. The new handle works, which is a relief.
I locked up the minivan and helped Lisa put away the tools. She says I should avoid using the electric door locks indefinitely, because she is concerned that they will strain some of the assemblies in a way that locking the doors with the keys will not. However, we do once again have full access to the rear cargo area, which is much better than taking things in over the rear seat.
This was the second time we've had to replace this part, and for the same reason: the pot-metal handle has a weak point and breaks. This time, though, Lisa knew where to start.
There is an insulation panel in the rear door that also holds the rear speaker for the sound system. It doesn't really appear to be meant to be removed, but you have to remove it in order to get at this access point in the rear cargo door.
Once she had the panel off, it was relatively easy for Lisa to reach inside and pull the cable that releases the rear door latch, allowing us to open the rear door. Lisa then put the insulation panel back as best she could.
Once we had the door open, Lisa tripped the latch so that if we accidentally let go of the door, it wouldn't lock shut again. This the door handle access panel, which is relatively easy to remove once you have the door open, but is completely inaccessible when the door is closed.
Well, there's your problem: This bit of broken metal is what broke off the handle. You can see where it engages with the cable that actuates the latch.
Here Lisa is holding the new rear door handle with the old one at right. She is also holding the bit that snapped off the handle up to the broken handle so you can see where it broke away.
It should have been easy to attach the new handle to the latch release cable and then reinstall the handle in this space on the outside of the door. But the aftermarket replacement did not quite fit, and it took Lisa 30 minutes of carefully bending things (without breaking them) to make it actually work.
That release cable should be straight, but if hooked up that way, would not cause the rear door latch to release when we pulled on the door handle. Lisa did manage to make sufficient modifications that it started working.
After testing it multiple times until she was satisfied that it would work, and confirming that we could indeed lock and unlock the rear door, Lisa sprayed some Liquid Wrench lubricant into the assembly, put the access cover back on, and closed the rear cargo door. The new handle works, which is a relief.
I locked up the minivan and helped Lisa put away the tools. She says I should avoid using the electric door locks indefinitely, because she is concerned that they will strain some of the assemblies in a way that locking the doors with the keys will not. However, we do once again have full access to the rear cargo area, which is much better than taking things in over the rear seat.
no subject
Date: 2023-01-22 11:45 pm (UTC)no subject
Date: 2023-01-23 02:07 am (UTC)