1. Assessment:
* Check the obvious: Make sure the handle isn't just frozen or obstructed by ice, debris, or something jammed against the door.
* Listen: When you try the outside handle, do you hear any clicking or sounds indicating something is moving but not connecting properly? This can help pinpoint the location of the problem.
2. Interior Door Panel Removal:
You'll need to remove the interior door panel to access the linkage. This usually involves:
* Removing screws: Look for screws around the edges of the panel, often hidden under small plastic caps or trim pieces.
* Disconnecting parts: There might be clips holding the panel in place. Gently pry the panel away, starting at the edges, being careful not to break any clips. Work your way around the perimeter, freeing the panel from the door.
* Unplug connectors: Carefully disconnect any electrical connectors (window switches, power locks) attached to the door panel. Take photos or make notes of the connections if you're not sure how they go back together.
3. Inspecting the Linkage:
Once the panel is off, you'll see the door handle mechanism and its linkage. Look for:
* Broken linkage: The most common problem. The linkage is usually made of plastic or metal rods and may have snapped or come loose from its attachment points.
* Dislodged parts: Small clips or pins might have become dislodged.
* Bent or distorted parts: The linkage might be bent, preventing it from working correctly.
* Worn-out bushings: Over time, the bushings that allow the linkage to move smoothly might wear out, causing binding or failure.
4. Repair or Replacement:
* Repair: If the linkage is broken, you might be able to repair it with a strong adhesive or a small metal bracket and rivets (depending on the break). If parts are simply loose, carefully reattach them.
* Replacement: If the linkage is badly damaged or worn, you'll likely need to replace the entire exterior handle assembly or at least the broken linkage rod. Parts can be purchased from auto parts stores (mention the year, make, and model).
5. Reassembly:
Once the repair is complete, carefully reassemble the door panel, making sure all clips and connectors are properly reattached.
Important Considerations:
* Door Lock Mechanism: In some cases, the problem might be within the door lock mechanism itself, not just the linkage. This requires more extensive disassembly and repair.
* Professional Help: If you're not comfortable working on car parts or are unsure about any step, it's best to take your Aerostar to a qualified mechanic. They have the experience and tools to diagnose and fix the problem efficiently.
* Online Resources: Search for "1995 Ford Aerostar door handle repair" or "1995 Ford Aerostar door panel removal" on YouTube or automotive repair websites. Videos can be extremely helpful in visualizing the process.
Remember to be patient and take your time. Rushing the process can lead to additional damage. Good luck!
