3rd Gen Grab Handle Fix DIY

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Fishstickz

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After years of prolonged use, a few days back my passenger side grab handle gave out. I decided to take a couple of pictures and write a how-to on how to fix it in case anyone else is looking for some answers

First off, these things usually break in 2 ways- the first being the entire crevice which houses the screws splits. This can usually be solved by using some hardware from Geno’s Garage https://www.genosgarage.com/product/imco-rpr-kit/interior-replacement-parts#reviews

The second way they break is the top plastic “cap” piece that holds the screw breaks off entirely. It will leave a big gaping hole where the screw is supposed to pass through, which doesn’t leave a lot of methods to fix. Luckily I found a video that showcased a pretty good method to secure the grab handle which is the method i used.
Here’s what you’ll need:

- Brass adapter. A 1/2” diameter outside thread on one end, and a barb-style fitting on the other end
- Small hose clamp

If you don’t have access to a table grinder or something to grind down the washer on the OEM bolts, you’ll need new hardware:

- 1 M6-1.0 24mm bolt
- 1 M6 washer

1. First thing you’ll do is clean out your newly formed hole. You aren’t gonna use the old plastic screw hole anymore, so be sure and take that off entirely. Here’s what mine looks like. Its scary thinking that this is the only thing supporting you when you’re getting in and out of your truck

e6fd8d4a115477337a8d019df5697590.jpg

2. Now you’re gonna wrap that hose clamp around the remaining plastic that used to hold that cap. Hand tighten it, you’ll fully tighten it down later
3. Take you’re brass fitting and cut off the barbed half. This will just leave the threads and a hole large enough for your bolt
4. Now take the fitting and screw it into the plastic. You want the hose clamp to be tight enough that the threads on your fitting are biting into the plastic. Screw it in until the fitting sits flush with the plastic
5. Tighten down the clamp with a small wrench. Remember its plastic so don’t go overboard

At this point everything should look similar this
896fb78bd89c077867270165a47ad5a8.jpg
cf5360b055c6c85075c259373da7250d.jpg

At this point, you’re done with the grab handle. Now you’ll have to work on the hardware. If your bolt and washer fits, great! You’re done. However chances are the washer won’t fit into the fitting all the way. If so, you have 2 options: either grind down the OEM washer, or use new hardware with a small washer. I chose to stick with the OEM stuff, so i took the washer to a table grinder until I got it down to an appropriate size.

Bolt it in and it should look pretty dang spiffy
d395d76828b9695f50e0a1d54d43ccd7.jpg

It feels much more secure now than the drivers side, which is just the OEM plastic. I’m going to buy the hardware from Geno’s for the other 3 bolts to prevent this sort of thing from happening again. Overall very satisfied, this 5-dollar fix beats buying a new panel that would likely fail again without additional reinforcement


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srv1

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I used the same video to fix mine ,(dr. sd.),about a yr. ago.Still holding strong!I ran the fitting in and out a couple times snugging up the clamp a little each time to get the threads to cut a little deeper.Repaired for 5.00 and better than new,thats what im talkin about.
 
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Fishstickz

Fishstickz

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I used the same video to fix mine ,(dr. sd.),about a yr. ago.Still holding strong!I ran the fitting in and out a couple times snugging up the clamp a little each time to get the threads to cut a little deeper.Repaired for 5.00 and better than new,thats what im talkin about.

Good to hear yours has lasted. The way you got some extra bite on in the plastic is probably the best way to go. A part of me wishes I would’ve thought about doing it that way but after putting 75% of my weight into the handle (I weigh in at 160) and not even a budge, I don’t think i’ll lose any sleep over it lol


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TOTALCHAOS69

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The entire top tube part broke off mine. I did the super glue and baking soda but don’t have much faith in it. It does feel pretty solid but I hesitate to put any weight on it. ‍♂️
 
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Fishstickz

Fishstickz

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The entire top tube part broke off mine. I did the super glue and baking soda but don’t have much faith in it. It does feel pretty solid but I hesitate to put any weight on it. ‍[emoji3603]

Yeah there isn’t much else you can do when it breaks like that besides buying a new one and hoping it doesn’t happen again. It was a horrible design from the start


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skippy344

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Yeah, mine broke on the driver side, and I did the sleeve/worm clamp fix, but....

The nutsert, in the A pillar is spinning freely, so I gotta find a way to fix that...

I am not sure how I am going to extract the current nutsert and install a new one such that it does not spin as well...
 

MikeT

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When mine broke, passenger side, two or three years ago I bought a new one from Geno's and two sets of the refurb kits that he sells. Replaced the passenger side and added the refurb kit to it. Then checked the driver side, it was cracked and pretty well on it's way to self destruct, I took a chance added the refurb kit to it and it has been fine since then. I still think about it just about every time I get in, but it has been solid as a rock since adding the kit. Very well worth the money. No problem at all on the passenger side either.

Mike
 

Fast69Mopar

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Yeah, mine broke on the driver side, and I did the sleeve/worm clamp fix, but....

The nutsert, in the A pillar is spinning freely, so I gotta find a way to fix that...

I am not sure how I am going to extract the current nutsert and install a new one such that it does not spin as well...
When the nut-sert starts to spin I usually can snug them up a bit with a bolt and a nut and compress it a little tighter. If it keeps spinning I still them out and install new ones. I bought this kit to test it out and it actually works really well...

https://www.amazon.com/RZX-Riveter-...ocphy=1026873&hvtargid=pla-704352505114&psc=1
 

skippy344

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Nice!!! That looks like a fix! Thanks for the suggestion!!

How do we get the old one out with out totally destroying the hole, and or the A pillar?
 

christoff

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Perfect timing, as my driver's side broke recently.

Great write-up, thank you.
 

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