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Replacing exterior door handle on 2002 Explorer

RICPDB

New Member
Joined
July 9, 2010
Messages
8
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0
City, State
Richmond, VA
Year, Model & Trim Level
2002 XLS
I recently replaced a broken exterior door handle on my 2002 Explorer XLS while also replacing the power window master switch. Below is a somewhat brief description of the door handle process. I was originally thinking that the door handle would be difficult, due to access, but it turned out to be pretty simple.

There are two nuts (11mm, go figure) holding the handle onto the door. The only other thing to remove is the rod that connects the handle to the door release mechanism. I removed the nuts first, but you could also remove the rod first, which may give you a little more room in there.

Nuts%20to%20remove.jpg


Remove%20first%20nut.jpg


Remove%20second%20nut.jpg


You need to release the bottom end of the rod in order to rotate it enough to get the hooked end out of the door handle.

Rod%20clip.jpg


Release%20rod.jpg


That's it! Reverse steps to install new handle and you're set. Try not to drop anything into the door. I spent a few minutes fishing around for a socket in there. By the way, the three screws holding on the door panel appear to be 5.5mm. I know... strange.

Good Luck!

old%20handle.jpg


 



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Very nice write-up.:thumbsup: Can you make the pics smaller? They don't fit on my screen.
 






Old as this post is, I wanted to thank you for the writeup! I just replaced my handle today (it broke at the same spot) and this was invaluable to figure out how to do it.
 






Great write up! Broke my handle off on the passenger door last week in the "Polar Vortex".

Job takes about 30 minutes.

I'd highly recommend getting an OEM part. The ebay one I have is fine...it just has more of a gap between the handle and the the base of the door panel.
 






Mine is the driver door handle on an 02 Explorer Sport. The major difference is that it is riveted in as opposed to the 11mm nuts.

Curiously, the replacement handle from RockAuto.com worked for about a week and then broke. So, I assumed I had a bad one. RA immediatly shipped a replacement gratis (not even shipping or return of the broken policy) so I was happy. But, the second handle broke after about three weeks.

On my way this weekend or next to a salvage yard to get another one. But, with the panel removed I will be trying to see any anomaly that could cause the breakage. If anyone has heard of this and knows the cause, please share.

Great pics btw.
 






Hope you get this. A big thanks on the pictures. I was rocking along until it came time to hook the rod back to the handle. The little yellow clip was confusing but your pic cleared it up. Thanks
 






Nice guide and pictures! I replaced an exterior door handle shortly after I bought my '05 XLT and it was a lot easier than I thought it would be. The original handle came broken when I bought her, and it was busted in the same way. I like how they bolt on for easy removal and are not riveted in like how they were on my '97 Ranger.
 






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