I now understand why this door handle lever broke off.
The rod which goes down to the latch is threaded at the upper end.
Look at the Adjustment Push Rod Nut in the following photo -
Those threads allow for the nut with the 90° side rod to be adjusted.
If it is not adjusted properly, the plastic handle lever pushes down on the rod
and
keeps pushing when the rod travels as far down as it goes.
Any further pressure upon lifting the handle just strains the plastic handle lever
until it breaks. This adjustment is
CRITICAL!
The Body Shop guy should have known this and adjusted it properly - he didn't...
Onward => I removed my Driver's Side Door Handle and inspected it.
Mine has one long hinge rod instead of two small ones. No worries!
I started tapping on the left side
The right side plastic Frame Arm started to bend - the rod was not coming out.
I had to tap it back into the proper position or it would have broken off!
I supported the right side plastic Frame Arm on the edge of my vice and tapped
the left end of the rod again.
The rod started coming out on the right side.
I finished by carefully pulling it out with a pair of pliers.
Here is the DS (L) Door Handle taken apart.
I will emery paper off the corrosion so that the pin goes back in easily.
I will also Instant Glue the pin back in place when I replace it. One little
drop on the right side should keep it from coming out...
Now to take the lever out of the PS (R) Door Handle....
I put the Handle frame into my trusty old vice jaws such that the pin is forced out
and
the pin can exit the other side....
Once it was protruding (don't force it too much or the plastic will crack), I grabbed it with
some gas pliers and pulled it out while twisting...
Here are the right and left side lever parts of the '93 Geo Metro Door Handles.
They are
Identical !
Now I can assemble the new lever into the DS Handle mechanism....the spring should be FUN!
But First! I am going to fix a big bowl of STAGG Ranch House Chicken Chili with Beans....
Melt some Cheddar Cheese in it and eat it all with a bottle of Beer to wash it down...
Working on car doors is thirsty work. Makes me hungry for Chili - my
favorite food!
DoctorBill
PS - I will show picture(s) of the "fixed" door handle in the next post - if all goes well.