Thomas rear door handle removal 94-97

[nikitis]

So I searched the forums but didn't find any knowledge of the rear emergency door handle removal process.

I need to remove mine to slide it out and reorient it so the inside handle swings down but I cannot figure out the proper way to disassemble it.

I see a pin like structure in the outside handle under it that is very thin and hollow. With no flat head, Alan shaped, or Phillips or star pattern to turn it to unscrew it out. I figure it's a pin but the metal is sooo thin if I put a hammer to it it will destroy it for sure.

I. The top side it looks more hardy but there is also no shape to the hole. Is this supposed to be an Alan wrench hole that maybe the previous installer stripped completely?

Do I have to unscrew it? Or is this something I just pick a side with a pick and hammer it out?

I'd like to know an answer before potentially ruining it.

Underside:

Top side:

 

[nikitis]

Update. It is just a thinly rolled thin steel pin. Not even a solid piece, but it did hammer out.

But even removed the handle is still stuck and I can't pry it off as it's soo tight against the door. Likely fighting 30 years of glue or something.

 

[nikitis]

Ok. I think this handle is welded into the bar because I put the mustard into this bar to pry it apart. If I had bent any further the door would of folded in two. That's how hard I pulled on it

It leaves me with no choice but I gotta grind the inner handle off and re-weld it in a different orientation.

 

[nikitis]

Transferred it down by grinding and welding it. If anyone knows how to take the black handle off let me know in this thread

 

[#1FordFan]

Transferred it down by grinding and welding it. If anyone knows how to take the black handle off let me know in this threadView attachment 1503943

I think to completely remove all moving part you would have to remove the rear handle AND grind off the river heads in the above photo.
I had to help remove one a few years ago. I can’t remember 100% how it was done.

I think the roll pin on the back handle was just/Only for the rear handle.

 

[nikitis]

I ended up just grinding off the leaver and re-welding it a different direction. Is working out fine.

 

[Mercuric Mind]

I struggled with that same rear door latch. Not fun at all. I ended up cutting the thing off to install a fancy keypad RV lock. Also made an "anti tamper" plate to protect the latch.

 

[nikitis]

I struggled with that same rear door latch. Not fun at all. I ended up cutting the thing off to install a fancy keypad RV lock. Also made an "anti tamper" plate to protect the latch.

Yeah the reason I kept mine was mainly because I like the amount of force it puts on the door when that latch closes. You need a lot of pressure to seal it properly. Since splitting it in two the upper half REALLY needs the added pressure because it doesn't have the weight of the lower half any longer.

 

[Mercuric Mind]

That is VERY true. I added some gasket foam as a shim on the top section to have any hope of it sealing.

 

[AlphaHare]

FWIW, the handle looks like this from the catalog. I haven't taken mine apart, but it looks like that by removing the spring pin and then prying the black handle off, you should be able to tap the square section back through the mechanism (maybe with a hammer).

 

[nikitis]

Yeah I tried everything. I tried a vice, crowbar, hammer, flatbar pry, it was welded or something, it didn't move a millimeter. If I had given it anymore force the handle would of snapped, so in the end for me it was easier to grind and reweld it in a different orientation.

 

[Ozbozz57]

Looks like you've found a solution. Nikitis. I re-worked both of my doors (rear and wheelchair lift) to add locks. After driving out the pin, getting the handle off the square shaft is a BEAR! If I remember right, I think I split the handles off with a chisel.

Thomas had a recall on the door latch mechanism. The square shafts rusted badly inside the door. I was able to get new handles, and I made new shafts from 1/2 inch key stock.

 

[Ozbozz57]

This is for the side wheelchair lift door. It's now access for under-the-bed storage from outside, and emergency egress straight off the bed.
I re-bent the inside handle so it cleared the added thickness of the insulation and interior skin. The lock operates from the inside only, can be done easily in the dark. Flipped down, the door cannot be opened.

 

[nikitis]

Your doors are top notch. Love the wood!