Door handle issues

[Wild Bill's ‘98 TJ]

Ok,
I am at wits end! A couple of weeks ago, when entering the driver door of my ‘98 TJ, it snapped in my hand. Turns out, it was the short small lever (in the door panel) that triggers the handle to trigger the latch/stricker. One had jumped past the other. I was able to go in and put it back. However, I knew it would do it again. So, I decided to order new exterior and interior handles as a combo and just upgrade them. Today, I changed them all out and tested everything dozens of times before putting the panels, pull handles, window crank, etc back on.
Tried Key lock and unlock, new interior lock and unlock, exterior handle, interior handle, and all combinations of open, close, lock, and unlock.
I put tools away and cleaned up. Got in it and drove down to my parents. After seeing to them I got in it and drove home. Everything worked as it should. Then, I locked it up for the night. Now, neither door will open from the outside or inside. I went in through the back window to see if they would open from the inside.
All clips, rods, etc looked good when I was inspecting during handle installation.
Why would they work repeatedly, and less than an hour later, not work at all?
A body shop buddy of mine is going to look at it tomorrow and see what he thinks. Any suggestions appreciated.
Again, all handles are new and worked perfectly before they suddenly did not.
Thanks!!!!!!

 

[williambmac]

I went through the same thing with mine last summer. I replaced the inner/outer door handles and latch. It would work fine for a few days then act up. I checked the rods to make sure they weren't bent. What I did find was, the lock rod lever at the lock cylinder has some play in it. The lock cylinder was worn. So, it would fully engage the latch at times.
Remove the door panel and disconnect the lock rod from the latch and retest it.

 

[mrblaine]

I went through the same thing with mine last summer. I replaced the inner/outer door handles and latch. It would work fine for a few days then act up. I checked the rods to make sure they weren't bent. What I did find was, the lock rod lever at the lock cylinder has some play in it. The lock cylinder was worn. So, it would fully engage the latch at times.
Remove the door panel and disconnect the lock rod from the latch and retest it.

There is also a clip in the middle of the rod that needs to be there to eliminate flex in the rod when they push on hard to move latch bits. I've seen a few of those cause issues.

Not that I doubt either of you are resetting the adjustable bits, but just need to make sure.

 

[williambmac]

There is also a clip in the middle of the rod that needs to be there to eliminate flex in the rod when they push on hard to move latch bits. I've seen a few of those cause issues.

Not that I doubt either of you are resetting the adjustable bits, but just need to make sure.

Mine had nothing to do with the clip, but I do concur. If the clip is missing the rods flex a lot and will eventually bend.

 

[Wild Bill's ‘98 TJ]

Ok,
I am at wits end! A couple of weeks ago, when entering the driver door of my ‘98 TJ, it snapped in my hand. Turns out, it was the short small lever (in the door panel) that triggers the handle to trigger the latch/stricker. One had jumped past the other. I was able to go in and put it back. However, I knew it would do it again. So, I decided to order new exterior and interior handles as a combo and just upgrade them. Today, I changed them all out and tested everything dozens of times before putting the panels, pull handles, window crank, etc back on.
Tried Key lock and unlock, new interior lock and unlock, exterior handle, interior handle, and all combinations of open, close, lock, and unlock.
I put tools away and cleaned up. Got in it and drove down to my parents. After seeing to them I got in it and drove home. Everything worked as it should. Then, I locked it up for the night. Now, neither door will open from the outside or inside. I went in through the back window to see if they would open from the inside.
All clips, rods, etc looked good when I was inspecting during handle installation.
Why would they work repeatedly, and less than an hour later, not work at all?
A body shop buddy of mine is going to look at it tomorrow and see what he thinks. Any suggestions appreciated.
Again, all handles are new and worked perfectly before they suddenly did not.
Thanks!!!!!!

Ok everyone,
My body shop buddy found the issue, kinda by happenstance on one door and then that gave us the solid answer on the other door. There is a threaded adjustment rod inside the door panel near the latch/lock mechanism. The adjustment of this rod affects how stiff the door paddle is (or how far the paddle moves when you open the door). Because the handles/paddles I replaced were old, worn, and loose, when I put the new ones in, the adjustment of that rod was too aggressive for the newer handles. Maybe this will help someone down the road. I will attempt to attach a photo of the rod.

Ok,
I am at wits end! A couple of weeks ago, when entering the driver door of my ‘98 TJ, it snapped in my hand. Turns out, it was the short small lever (in the door panel) that triggers the handle to trigger the latch/stricker. One had jumped past the other. I was able to go in and put it back. However, I knew it would do it again. So, I decided to order new exterior and interior handles as a combo and just upgrade them. Today, I changed them all out and tested everything dozens of times before putting the panels, pull handles, window crank, etc back on.
Tried Key lock and unlock, new interior lock and unlock, exterior handle, interior handle, and all combinations of open, close, lock, and unlock.
I put tools away and cleaned up. Got in it and drove down to my parents. After seeing to them I got in it and drove home. Everything worked as it should. Then, I locked it up for the night. Now, neither door will open from the outside or inside. I went in through the back window to see if they would open from the inside.
All clips, rods, etc looked good when I was inspecting during handle installation.
Why would they work repeatedly, and less than an hour later, not work at all?
A body shop buddy of mine is going to look at it tomorrow and see what he thinks. Any suggestions appreciated.
Again, all handles are new and worked perfectly before they suddenly did not.
Thanks!!!!!!

Ok,
I am at wits end! A couple of weeks ago, when entering the driver door of my ‘98 TJ, it snapped in my hand. Turns out, it was the short small lever (in the door panel) that triggers the handle to trigger the latch/stricker. One had jumped past the other. I was able to go in and put it back. However, I knew it would do it again. So, I decided to order new exterior and interior handles as a combo and just upgrade them. Today, I changed them all out and tested everything dozens of times before putting the panels, pull handles, window crank, etc back on.
Tried Key lock and unlock, new interior lock and unlock, exterior handle, interior handle, and all combinations of open, close, lock, and unlock.
I put tools away and cleaned up. Got in it and drove down to my parents. After seeing to them I got in it and drove home. Everything worked as it should. Then, I locked it up for the night. Now, neither door will open from the outside or inside. I went in through the back window to see if they would open from the inside.
All clips, rods, etc looked good when I was inspecting during handle installation.
Why would they work repeatedly, and less than an hour later, not work at all?
A body shop buddy of mine is going to look at it tomorrow and see what he thinks. Any suggestions appreciated.
Again, all handles are new and worked perfectly before they suddenly did not.
Thanks!!!!!!

 

[Wild Bill's ‘98 TJ]

This is the door handle adjustment that can keep your doors from locking, unlocking, or opening.

 

[taylormade73]

There is also a clip in the middle of the rod that needs to be there to eliminate flex in the rod when they push on hard to move latch bits. I've seen a few of those cause issues.

Not that I doubt either of you are resetting the adjustable bits, but just need to make sure.

Should’ve doubted.

 

[mrblaine]

Should’ve doubted.

I thought it was obvious.

 

[taylormade73]

I thought it was obvious.

‘Twas to but a few.

 

[Wild Bill's ‘98 TJ]

No need for arrogant sarcasm!
These threads are meant to be helpful. Thanks for all the civil responses. Not so much for the others.

 

[billiebob]

Same, just did this, a bit of lube makes a huge difference but getting access is painful.

After taking it apart I drilled 2 holes to get better access,
Now it will be simple to lube the latch every year.

My intereior lock/unlock mech was also sticky, same thing after 17 years it was due for some lube. Works like new now.