DIY: 02-05 Explorer Driver's side OEM grab handle install w/pics

[rdop02xlt]

Decided I needed to be grabbing a handle instead of the steering wheel when getting in/out of the truck with all the snow and ice this winter. I found a 04 OEM handle and A-pillar trim piece from Ebay for $24 shipped. My truck is a 02 and everything lined up fine. All said and done this project took about three hours and $30 to complete.

First thing to do was to gather the tools, parts, etc. I used 1/4"-20 Allen head bolts to secure my handle. I found the jack nuts at my local True-Value hardware store.

The long screw, nut, washer, and flat steel tool will be needed to install the jack nuts. I would recommend getting a couple extra jack nuts just in case you over-tighten or strip out the threads. http://www.thread-rite.com/pop_nuts/jack_nut_installation.htm Also, you will need basic hand tools, an electric drill with a Uni-bit (AKA step drill), a Dremel or equivalent rotary tool(preferred, but I suppose you could use hand files).

Next was to remove the driver's A-pillar trim piece and locate the two existing square holes where the handle will bolt to. At this time, pop out the wire clips and disconnect the green connector(visible @ extreme right of the next pic) to get this wire out of your way. Using my Uni-bit, I VERY slightly rounded out the holes so that the jack-nuts would fit.

the jack nuts installed...

Once I had successfully installed the jack nuts (it is a PITA due to the proximity of the windshield) I test fit the handle.

Now onto making holes for bolt access and the handle mounting arms. Using the passenger's side trim piece I got from Ebay, I made a template with some card stock paper.

Transferring the template to my driver's side trim piece, I first used my Uni-bit again to remove the lion's share of material and then finished up with my Dremel.

Use caution when test fitting everything as I managed to snap off one of the metal clip retainers on the driver's side trim piece. After a few test fits I was pleased with the final product. The handle has a slight angle to it since it was meant for the passenger side, but I can't tell unless looking closely.

Hope you enjoyed my first attempt at posting a DIY. My many thanks to this forum/mods/members as I have practically rebuilt my truck from this forum's information.

 

[wbrudi28]

this is awesome. I really wonder why there isn't one stock there...i could sure as hell use it (only 5'7).


unfortunately I cant because i mounted a 4D Maglight there

 

[Number4]

So the mounting holes were already there then?

 

[Danfromwis]

Thanks been thinking of doing just this same thing but not for to get in! Wanted a handel on it there since watchin a Dillinger Movie a couple weeks ago! Was getting the drill up in there by the windshield a Pain in the? My luck I would get a catch an wack my windshield a nice crack! but eather way great write up! And Pictures

 

[Explorer0204]

this is awesome. I really wonder why there isn't one stock there...i could sure as hell use it (only 5'7).

unfortunately I cant because i mounted a 4D Maglight there

Any pictures. That sounds interesting.

 

[wbrudi28]

Any pictures. That sounds interesting.

http://www.amazon.com/MAGLITE-ASXX3...8-3&keywords=maglite+d+cell+mounting+brackets

this kit is what i purchased.

 

[Explorer0204]

http://s5.photobucket.com/user/wgpo4/media/IMG_4214.jpg.html

http://www.amazon.com/MAGLITE-ASXX376-Accessory-D-Cell-Flashlight/dp/B000056BMY/ref=sr_1_3?ie=UTF8&qid=1394668767&sr=8-3&keywords=maglite+d+cell+mounting+brackets

this kit is what i purchased.

Hmm I like that. What prompted you to put it there I never thought of doing that.

How do you like your spot mirrors on the bottom? I have mine on the outside top and they are awesome!!!

 

[wbrudi28]

Hmm I like that. What prompted you to put it there I never thought of doing that.

How do you like your spot mirrors on the bottom? I have mine on the outside top and they are awesome!!!

i go offroading on the beach to go surfcasting, and where i go people leave small fires (illegal) partially exposed, theres bits of metal from the fences, broken beach chairs, or sometimes unidentifiable things on front/around my truck so having this is my version of a police spotlight haha

 

[rdop02xlt]

Yes, there are two square holes already punched from the factory.

 

[Number4]

Yes, there are two square holes already punched from the factory.

Makes sense. These bodies are produced for right hand / left hand drive I believe.

 

[Number4]

Yes, there are two square holes already punched from the factory.

You stated that the handle is at a slight angle. Though not really noticeable. Can this be avoided?

 

[rdop02xlt]

I should have been more specific when I said there is an angle. When you look closely at one of these handles, one "leg" has a slight angle to it - the legs are not exactly parallel to each other. This angled leg goes from the upper position on the passenger side to the lower position on the driver's side. Way too small of a difference to notice unless you really look.

 

[Number4]

Hey, what's the tool do? Can I get by without it?

 

[rdop02xlt]

Sorry for not replying promptly. I couldn't get the jack nuts to tighten correctly without the installation tool. I'm sure something could be fabricated at home but for the couple bucks it cost to get the tool I figured it was worth it.

 

[Number4]

As it wasn't available in town, I modified a Simpson tie for the purpose. Having removed my running boards, I use this mod all the time.