* Handle itself is broken: The plastic or metal handle might be cracked, broken off, or severely worn.
* Internal mechanism is broken: The latch mechanism, the connecting rod, or the spring inside the door might be malfunctioning.
* Handle is loose: The screws holding the handle might be loose or stripped.
Here's a breakdown of how to approach the repair, assuming you have basic tools (screwdrivers, possibly pliers):
1. Diagnosis:
* Open the door: See if the problem occurs when the door is open or closed. This will help pinpoint if the issue is within the handle mechanism or further into the locking system.
* Inspect the handle: Look for cracks, breaks, or loose screws. Try gently moving the handle to see where the problem lies – is it the handle itself, or is the mechanism not responding?
* Listen for sounds: If you try the handle and hear clicking, grinding, or other unusual noises, that indicates a problem with the internal mechanism.
2. Repair Options:
* Loose Screws: If the handle is loose, simply tighten the screws. If the screw holes are stripped, you might need to:
* Use wood glue and toothpicks: Fill the stripped holes with wood glue and toothpicks, let it dry, then re-drill slightly smaller holes for the screws.
* Use screw inserts: These are small metal inserts that can be glued into the stripped holes to provide a better grip for the screws. They're available at most hardware stores.
* Broken Handle: The most straightforward fix is to replace the entire exterior door handle assembly. You'll likely need to:
* Purchase a replacement: Find a replacement handle specifically for a 1993 Ford E150 cargo door. Your local auto parts store or online retailers (like Amazon or eBay) will be your best bet. You might need the part number from a Ford parts diagram.
* Remove the old handle: Carefully remove the screws holding the old handle in place. Take pictures before removing anything to help with reassembly. You may need to remove interior trim panels for better access.
* Install the new handle: Follow the reverse process of removal to install the new handle, ensuring all screws are tightened securely.
* Broken Internal Mechanism: This is the most complex repair. It often requires:
* Removing the door panel (interior): This allows access to the internal components of the handle and locking mechanism. You might need to remove some screws and disconnect clips. Search online for "1993 Ford E150 cargo door panel removal" for detailed instructions with pictures.
* Identifying the broken part: Once you have access, inspect the internal parts for breakage. You may need to replace the entire latch mechanism, connecting rods, or springs.
* Replacing the broken part: You might need to order specific replacement parts from a Ford dealership or a salvage yard.
* Reassembling the door panel: Carefully reassemble the door panel and connect all the components.
3. Resources:
* Online Parts Stores: Search for "1993 Ford E150 cargo door handle" on online retailers. They often have diagrams and part numbers to help you identify the specific parts you need.
* Ford Dealership: A Ford dealership can provide parts and potentially some repair advice. They will have access to detailed parts diagrams.
* YouTube: Search for videos on "1993 Ford E150 cargo door handle repair" or "1993 Ford E150 cargo door panel removal." This can be invaluable for visualizing the process.
Important Note: If you're not comfortable working on vehicles, it's best to take your van to a qualified mechanic. Improper repair can lead to further damage or safety issues. Remember to always disconnect the battery negative terminal before working on any electrical components.
