The little white clip that connects the exterior driver's door handle to the latch keeps failing and slipping on the threads of the connecting rod that actuates the latch. When it fails, I can feel it give out as I'm pulling on the handle, and it just loses its connection to the latch. I've taken the door card off and reattached it three or four times. The last time I did this I think I put too much tension on the connecting rod, because it somehow disengaged the interior and exterior door latch. I thought the door was super locked (which I'll stop doing after reading all those threads...), but I could hear both motors working to unlock the door. After playing with it, I finally have my door open, but now I'm not sure how to properly set the clip, or if there's some solution to stop it from slipping constantly. Has anyone else run into this?

Thank you for your help, as always.

 

I don't know much about the inner workings of the door latch. I am due to replace my door actuator motor. I found this detailed video which I will be useful to help me with the project next week.

Perhaps this video may also be useful for you. Are you referring to the white/black assembly in minute 5:58 of this video?

 

No, that's not what I'm having difficulties with. I actually don't see my problem piece in the video anywhere, which is strange. I took a picture on a spare door I have. You can see the connecting bar that comes down from the exterior door handle with maybe an 1.5" of threads at the bottom. The white plastic piece that hugs it keeps slipping off the threads. I've thought about putting a couple small zipties around it to hold it together better, but I'm not sure how to confirm that it's in the right position. My doors are very temperamental. A couple times I've tested them with no issues, only to have this bit fail as soon as the door card goes back on.

 

I’ve had to correct mine a couple times. Not sure if it was just not adjusted right, so I would loosen the clip and push up taking the play out of the rod then lock it back in. Hear what you are saying about yours slipping. You may be able to get a new clip from rovers north…used handle assembly from roverlandparts or eBay if you think threads being worn down are the issue. Also, I don’t see why you couldn’t thread 2 small nuts all the way up to the top of the thread on the rod so they lock in place against each other.

 

That is a brilliant idea! And it's so obvious, as most great ideas are! I'll take the rod out of my extra door and take it to the hardware store to find the right size nut. Thanks!

 

Could you put a nyloc nut and a washer on the bottom of the rod to keep the rod from pulling out of the white plastic piece?

 

Well we should probably wait to see if it works :-)

 

Mendenhall did you have any luck ?

 

No luck yet, as I just got back from vacation and so haven't thought about the Discovery in a couple weeks haha! I will definitely update everyone when I have something to report.

 

No worries. Was just wondering.