Door handle problems...SOLVED

After the paint guy removed my driver side exterior door handle, it failed to function properly. The handle must be lifted much to high before releasing. I purchased a new handle and installed that. At first, I thought it was better and reinstalled door panel but I see I am having the same problem. Looks like the lock button wants to push down when lifting handle. Like it’s binding on the other rod. Does anyone have the ability to take a close up picture of the handle and rods from the inside? Perhaps I am missing a spacer or bushing? Otherwise, I will have to remove passenger door panel too to compare. BTW, I have manual locks and windows.

 

i had to remove the plastic shield that protects the door lock. it kept binding after i removed it to fix door handles. try that. it just slides out. if it gets better then you may have to leave it out our get a new one that isn't deformed other wise try lubing the pivot points. sorry i don't have a picture of the inside right now.

 

There are some decent threads on here and videos on YouTube about how to remove, clean, and replace Gen 1 door handles. Try some searching and you'll likely find plenty of information to help.

And of course you have the other side of the truck to compare to.

Doesn't sound like the handle is the problem, unless it's not seating correctly. Might have something to do with the rods connecting the handle to the latch/lock.

 

I don’t recall a plastic shield covering door lock. I know I didn’t order one when I ordered the new door handle. Perhaps this shield would prevent the binding?

 

really? on my 2001 there is one the extends down from the physical lock lever that you can push down to lock or unlock the door manually. the linkage goes inside this shield and prevents use of a slim jim or other theft device to unlock door from outside. it might be kind of hidden between door and window.

this is a picture of a 4 runner door but the piece in question is in the upper left corner

 

Interesting. I do not recall that. Maybe they started installing after 1999, or maybe it was tossed when he removed lock. I guess I’ll have to open up passenger side and look. I have no problems with that side. There was also a little white plastic washer that was cracked and fell out where one of the rods connected to door latch lock assembly.

 

I replaced my door handle a few months ago. This video helped me with the process and shows the lock & open linkages:
https://youtu.be/RNprmUQhqRw

 

One of my trucks I had to pull the handle all the way just to get it to open . I took a pair of pliers and put a kink in the linkage rod and it worked great.

 

I already replaced the door handle with a new Toyota part ($99) but that didn’t fix it. It looks like the rods on the door latch assembly got bent. I tried straightening out but it looks like part of a nylon bushing with a little spring is broken off as well. I just ordered the new latch from Toyota ($155)...ouch! I let you all know if this fixes the problem.

 

Keep us posted!

 

Following. I had door handle issues for a very long time. I tried everything but replacing the main assembly including bending the rods, replacing the clips, new door handles etc. What fixed it for me was greasing the hell out of everything with some "waterproof" Belray grease. Not white lithium grease but the thick stuff. Especially the -plastic on metal- slider on the door hande. Works smooth now

 

Turns out the Latch Lock Assembly P/N 69320-04010 was the problem. One of the rods were bent connected to the lock assembly and a nylon washer was missing at the same location which allowed more slop in the rod. I presume my painter bent the hell out of it attempting to remove the door handle as there was zero issues prior to having it painted. I wasted $100 plus tax on a new oem door handle with no results before replacing the lock assembly which was a PITA to remove/reinstall. I’ve attached a pic of the new assembly and circled the area that was bent/missing on the previous one. This picture is the new one (what it should look like). Hope this helps anyone having similar issues.

 

Thank you. This was a very helpful post!