Rear Ambulance Door Handle Asm R&R (1 Viewer)

[michaelharrisco]

I'm really just looking for any tips to make life easier here...I think at the end of the day I'll be able to handle this, but foresee trouble.

Goal: replace inner rear ambulance door with a CCOT replacment (I know some of you hate the CCOT handles, but it was a gift and it will be much better than what I have).

Problems I'd like feedback on:
1) PO painted the entire assembly with the handle on the door so I'm concerned 4 screws could be really tough to get off. I've read the "rusty bolt removal" section in FAQ. Does anyone else have further recommendations for this specific assemble or should I continue throwing PB blaster and heat at them?

2) The existing exterior handle is loose in the door. I'm curious if anyone has ever found a shim type part at a local hardware store that I could put around this to tighten it up.

Bonus: I'm going to look to see if I can take out existing lock assembly and get a key made. Ideally it would match ignition and front doors. Anyone had luck with that? It is there, but again kinda buried with paint from the PO messy paint job.

Any other general thoughts?

Pictures for reference of what I'm looking at.

 

[FJsnoozer]

1. I like to do one turn tighten about a 1/6th of a turn, then un screw. This will break the bond in most cases on screws. I got all of the rusted windshield frame hinge screw out this way. I also like to use an allen head bit with a 1/4 drive driver bit and socket wrench instead of a screw driver.

2. It is very easy to take the door lock cylinder out yourself and I would just replace it with a toyota piece for 30ish bucks or so. The dealership can get it for you. there is a pin with a ring to pull on that holds the lock in place. The only thing I could see if the paint shipping when you push the lock out. You might exacto the paint around the lock prior to removal.

 

[bj40green]

Use an impact screwdriver. Let somebody hold the door when you do this.
If that doesn't work, use a Dremel with a cut off wheel to make a deeper and wider Philips head. Last option: cut off or drill off the head.

The key is different from the ignition and other doorlocks. It's much smaller. Buy a new lock at the dealer. It comes with 2 keys.

Rudi

 

[michaelharrisco]

I like the idea of buying a new lock asm and will probably go that route.

Onto the next issue I just realized. The nut that held on the exterior door handle that comes in is broken off. Am I out of luck and will be forced to buy a whole new rear door handle assembly? I'd love to know if there is a way to repair what I have before I take it off.

I included a new circle around the same pic that highlights the broken nut I'm talking about.

Any experience with this or is it a known deal that I'm going to have to buy a new handle so the treads go through the back of the ambulance door handle asm so I can put a nut on?

I'm going all SS on this replacement (like I always do) so this stuff doesn't get covered in rust and seize up!

 

[Toshi38]

Once you remove the rest just weld a nut on and back it off... or use vice grips ...

 

[Pearly]

Get a pointed instrument or anything sharp and dig the paint out from the screw heads - this allows more purchase of the driver.

 

[sggoat]

for the door handle, if the nut took off most of the handle threaded stock, you COULD-weld on a new piece of rod, dress it up, then rethread it--I think it is M6x1, but not sure. As long as the square stock is ok going through the handle gear. Another option might be to drill into the center of the handle rod and tap it- it will be a small screw, but all you really need is something to keep the handle positioned so the square shank is is in good contact with the door gear

 

[FJsnoozer]

I hammer the screwdriver once or twice into the groove. This is enough to crack out and remove the paint from the groove.