@Chris
Many TJ owners have experienced door handle and latch problems because the various rods use plastic retainer clips that over time weaken, break, etc. It can be difficult to find the correct plastic clips, and you may have my experience in which the new clip does no better than the old (clips cracks, rod still pops out of door handle hole, etc.) If you need a replacement clip (I needed the yellow one that retained the outer door handle rod to the mechanism), you can find Dorman part #75450, which is an assortment that has the yellow retainer in question.
BUT, if you prefer what I feel is a permanent solution do the following:
1. remove the rod and discard the plastic yellow retaining clip
2. place the rod in a vise with the end that inserts down into the door handle pointing up
3. use a size 10-24 die and a few sprays of WD-40 to cut male threads
4. you may need to bend the rod to allow for the handles of the dies to rotate fully (take a photo of the rod prior to bend back correctly)
5. purchase the appropriate sized nylon bushing and a 10-24 nylon locking nut
6. cut down the nylon bushing if need be, install rod, tighten nut but allow for some pivot movement
7. reattach other end of rod into metal retainer clip and check for correct outer door handle action
8. replace the inner door card (FYI- the replacement door card clips you'll probably need because half of them broke are Hillman 468850)
Many TJ owners have experienced door handle and latch problems because the various rods use plastic retainer clips that over time weaken, break, etc. It can be difficult to find the correct plastic clips, and you may have my experience in which the new clip does no better than the old (clips cracks, rod still pops out of door handle hole, etc.) If you need a replacement clip (I needed the yellow one that retained the outer door handle rod to the mechanism), you can find Dorman part #75450, which is an assortment that has the yellow retainer in question.
BUT, if you prefer what I feel is a permanent solution do the following:
1. remove the rod and discard the plastic yellow retaining clip
2. place the rod in a vise with the end that inserts down into the door handle pointing up
3. use a size 10-24 die and a few sprays of WD-40 to cut male threads
4. you may need to bend the rod to allow for the handles of the dies to rotate fully (take a photo of the rod prior to bend back correctly)
5. purchase the appropriate sized nylon bushing and a 10-24 nylon locking nut
6. cut down the nylon bushing if need be, install rod, tighten nut but allow for some pivot movement
7. reattach other end of rod into metal retainer clip and check for correct outer door handle action
8. replace the inner door card (FYI- the replacement door card clips you'll probably need because half of them broke are Hillman 468850)
