S10 Truck, new aluminum third-door handle, for 1996–2003
Chevrolet S10 and GMC Sonoma extended cab trucks,
this part is designed and manufactured by Stealth Conversions

The handles for the third-door (or cargo door) are injection molded plastic. While cheap to manufacture, light-weight, and rattle-free, they are notorious for breaking.

replacement handle developed by Stealth Conversions

Stealth Conversion’s replacement third-door handle is made in America, from heat-treated aircraft aluminum, which will not break.

The handle was designed to have the same travel limits and feel as the stock plastic handle.

The plastic handle provides lubricity between the moving parts. The aluminum handle requires grease to function smoothly. The rounded contact suface helps retain grease. The holes for the pivot pins are carefully machined to prevent rattling, while leaving enough clearance to retain grease.

The handle is light-weight so that it will not rattle — it weighs about the same as the plastic handle.

Tools for installation of handle

Tools Required:

• T-30 torx
  
• small knife or small flat screwdriver (not shown)
  
• needle nose pliers (bent nose preferred)
  
• socket
  
• 1/8" or 3/16" punch (a small screw driver, or a nail can be substituted)
• small hammer.
  
• small hammer
  

A knife is used to remove handle assembly.

REMOVING HANDLE ASSEMBLY

Remove the screws with a torx driver (size T-30).

After removing the torx screws, use a small knife (or small screwdriver) to gently pry the handle assembly from the door.

Removing the Clip

Maneuver the handle assembly to get access at the plastic retaining clip (arrow).

Gently squeeze the retaining clip with a needle-nose pliers, as shown, so it can be detached from the handle assembly.

Removing second clip

Maneuver the handle assembly as shown, for access to the second clip.

After removing the second retaining clip, remove the handle assembly from the door.

Pivot pin removal

REMOVING PIVOT PIN

Place the handle assembly up-side-down on top of a socket, as shown, so the pivot pin can be removed.

Gently hammer on the pivot pin with a 1/8" or 3/16" punch as shown. A nail or a small screw-driver can also be used.

Do not use pliers to remove the pivot pin from the housing, or it may nick the pivot pin, and cause installation problems.

Handle and pin grease points

Test fit the pivot pin into the aluminum handle as shown to insure that it slides into place, and spins easily.

If the pivot pin does not easily slide into the handle, check for nicks or scratches on the pivot pin. If any nicks or scratches are found, use a file or sandpaper to smooth the rough spots.

After insuring the pivot pin slides into the aluminum handle, put some grease in the pivot holes, and the area the arrow points to.

Install the aluminum handle into the plastic housing.

Install the pivot pin, noting that the serrated portion of the pin goes on top.

Gently tap the pivot pin into the plastic housing until it is fully seated.

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Handle assembly installation

INSTALLING HANDLE ASSEMBLY

Install the plastic clips onto the handle assembly.

First, attach the lower rod to the handle, as shown, using your finger to seat the retaining clips.

Next, attach the upper rod.

Maneuver the handle assembly into the door.

Finished

FINISHED INSTALLATION

Fasten the handle assembly to the door with the torx screws, and verify the handle works properly.

If the door does not open properly, remove the handle assembly and adjust the position of the plastic retaining clips on the pull rods. Ideally, the door should open when there is about 1/4" to 3/8" of clearance between the aluminum handle and the side of the plastic housing.

The finished installation has an attractive appearance.