How do you change the outside rear door handle on a 1993 safari van?
"Safari/Astro_broken_rear_door_handle">Safari/Astro broken rear
You will need: an electric drill, 1/4" drill bit, 2- 1/4" x 2"
bolts, 2 flat washers, 2 lock washers and nuts or flat washers and
lock nuts. When you move the handle aside you will see what looks
like two rivets; these are the heads of the bolts holding the
handle to the door. Carefully drill through these bolts, you may
want to centre punch the heads first. These bolts are made of
aluminum so the drilling isn't too hard. Once this is done the
handle comes off and you can reach in and activate the push-rod
that opens the door. With the door open, look on the inside edge of
the door and you'll see a small plate with four Philip's screws
holding it. Remove this and you can see inside to replace the
handle. I was able to repair my handle dilling out the mount with
the "cast in" bolt and fit another bolt to attach the pivoting part
(bellcrank) to the handle. The main problem with this handle is
that it is made of cast aluminum and thus wears out with frequent
use. Install the handle with it's gasket using the 2" bolts making
sure the pivot and push-rod work smoothly. A little grease at the
contact points helps. To make opening the door easier, try pushing
gently but firmly on the door just above the door handle as you
pull on the handle to open it.