Hey folks. I recently attempted to repair the door latch cables on my 08 E250s barn doors (side doors on passenger side, non sliding). I did this by replacing the cracked plastic ends with metal ones from Dorman.

however, after closing the doors, I can’t get them open again. The cables seem to be fine, but I think I got the lock in some bad state where it’s stuck shut. If I try to pull up on the lock rod, it moves up but does not latch, and it falls back down if I let go.

another thing I noticed is that the ball end of the cable is loose for the interior handle. I believe it should be under tension at both sides, and a spring should be holding it on the latch side. In other words, it’s as if the door handle is being held open from the perspective of the latch.

my thought is that the metal ends I put on are shortening the cable, which made the latch not fully seat as “open” and this is somehow interfering with the lock. Does that make any sense? If so, I’ll have to just cut the cable and start over. But, im hoping not and it’s something stupid im missing.

any help is greatly appreciated.

 

It has been my experience that the Dorman solution is short lived even if you get it right the first attempt. I have now started replacing the entire cable set. If you go to fordparts.com and use your VIN # to search, you can find the part #. Then google the # to find the part. The are still available.

 

When you get a chance, check at the bottom of both doors. If any parts came off they would be sitting in the bottom of the doors.

 

Check https://www.ebay.com/itm/392036075175
And never replace just the cable end.
Their Item description as follows:
Brand New 2 pcs cable set for Side Cargo Double Door (RH) Toward front door. By using this MotorKing Cable Set save time and money last longer the OE.
Tech Note: Common problem 1992 - 2014 Ford Econoline series vans common problem, door won't function properly, This is caused by door latch or handle cables being broken. MotorKing chooses metal ends instead OE plastic, also using upgraded heavy duty cable tubing's.
Dealers do not offer cable separately, it's only available in complete expensive latches or handle assemblies, those plastic cable ends will eventually break again!
MotorKing recommends replacing our complete metal cables instead of only fixing the cable ends, due to original cable / wire being bent or damaged which will cause restriction or cable binding effecting door handle or latch system from functioning.
MotorKing's Improved Design Metal Cable repair kits is designed to save you money, time and it lasts longer than OE designs.

 

thanks. I got it figured out. The cable was indeed holding the latch open, which prevents the lock rod from going up. I detached the handle end of the cables, then used a screw driver to push the spring back and “close the handle”. that allowed me to unlock the door & open it. Pretty sure these Dorman ends and shortening the cable which is how I got it in this state in the first place.

ill keep messing with it, but I’ll probably end up buying the replacement cables from ford.