Ford Transit Rear Door Exit Handle Kit (36″ to 64″ Above Floor)

Benefits

Campervans with elevated platform bed and garage underneath is a very popular configuration (we love ours!), but access to the factory exit handle(s) is lost (because factory handle(s) are too low) and it’s then impossible to open the rear doors from the platform bed.

This kit adds an extra handle to the rear door latch mechanism and enables to open the door from above the platform bed for your safety/convenience. The entire mechanism lives inside the door structure, so only the handle is visible. It’s an important yet low-key modification:

Included In This Kit

This kit includes all the parts/hardware required for the installation:

• 1 x Handle Assembly (with pre-installed self-adhesive VHB pad*).
• 1 x Galvanized Steel Cable (90in/2.3m)
• 1 x Cable Housing (72in/1.85m).
• 1 x Cable Housing Retainer.
• 2 x Aluminum Cable Stop Sleeve.
• 1 x Aluminum Cable End Cap.
• 1 x Drill Guide.

* Recommended for metal surface only. The VHB tape will most likely not hold on other surfaces such as wood, plastic, fabric, etc.

Tools Needed

• Long-Nose Pliers.
• Cable Cutter.
• Power-Drill with 5/64″ Drill Bit.

Installation

1. Remove the plastic panel on the passenger-side Rear door

The plastic panel is held by push-pins around its edges. Pull hard all around the edges to disengage them (don’t be shy, this will not damage them!). You can start with a plastic scraper to make it easier.

2. Partially remove the dust/weather protection sheet

The dust/weather sheet is held with a thick bead of black gunk around its edges. Slowly pull it away from the door to partially remove it (try to keep it free from dust and grease so it stays sticky for reinstallation):

3. Install the cable housing retainer

Slide and clip the cable housing retainer into the circular cutout (from behind):
* Be careful not to drop the retainer into the door! 🙂

4. Drill a hole in the Latch handle

Prepare the latch handle to receive the steel cable by drilling a small 5/64″ hole into it. The ideal location of the hole is ~17mm from the front of the handle; this is to ensure that the steel cable is routed behind and is not visible.

We included a small drill guide to help you locate and drill the 5/64″ hole at an angle:

5. Install the cable housing

Route the cable housing from top to bottom and take advantage of the natural curves in the housing to guide it towards the door’s center cutout:
* Remove the handle and steel cable from the housing to make this a bit easier!

Route the housing towards the housing retainer with large smooth curves (sharp curves increase friction between the cable and the housing):

6. Route the steel cable

Feed the steel cable into the housing from the top until it comes out at the other extremity (out of the retainer). Then route the cable from the retainer into the hole drilled previously:
* To make it easier, use a flashlight and look inside the door cutout. You can actually see the hole from there!

7. Install the Handle

• Clean the surface of the door with Isopropyl alcool, let it dry 30-60 seconds.
• Remove the release liner from the VHB tape and apply pressure for 5-10 seconds to create a strong bond.
• Let the VHB tape cure for 20 minutes. You can continue the installation but don’t “test” the system (Step 8.5) before the VHB tape had at least 20 minutes to cure!

8. steel cable Final Installation

8.1. Slide the aluminum stop sleeve into the steel cable and let it loose (do not crimp now):

8.2. Make sure the cable housing is inserted INTO the handle and into the retainer, then pull on the steel cable. This forces the cable housing to fully sit into the handle and into the retainer, removing any slack/freeplay from the system.

8.3. Make sure the latch handle is fully at rest, keep pulling gently on the steel cable, then use long-nose pliers to crimp the aluminum stop sleeve temporary so it stays in place until its final crimp:

8.4. Fully depress the latch handle and pull the cable out to expose the aluminum stop sleeve. Now that we have a better grip, we can fully crimp the stop sleeve (use maximum force!):
* Alternatively you can use vise-grip pliers to make the crimp easier.

8.5. At this point the exit handle mechanism is operational. Test it and make sure it works as intended (only if the VHB tape had at least 20 minutes to cure)!

8.6 (optional). If there is too much freeplay to your liking, you can remove the aluminum stop sleeve and repeat steps 8.2. to 8.4. To remove the stop sleeve, use pliers and gently crimp it in the other direction (to make it round again) then use pliers to slide it out of the cable. Discard the old stop sleeve and use the 2nd one provided in the kit.

8.7. Depress the latch handle to expose the cable and use cutters to trim the cable (10mm after the stop sleeve). At last, use pliers to crimp the end cap.

9. Reinstall the dust/weather sheet and the plastic panel

10. You made it! Final Result:

Compatibility

This raised handle kit is compatible with:

• Ford Transit cargo vans (2015 -present).
• Rear doors with metal surface. The 3M VHB tape will NOT adhere and stay on any other surface than metal (wood, plastic, etc.).

Specifications

• Handle Assembly Dimensions: 1.65in x 1.65in x 1.0in (38mm x 38mm x 24mm).
• Manufacturing:
  • Handle & Housing Retainer: 3D Printed.
  • Steel Cable & Housing: Bike Derailleur Hardware (available at any bike shop).
• 3D Printed Material: Blend of Polycarbonate (50%), PETG (45%) & others (5%).
• Temperature Resistance: Up to 230F (110°C).

Cable Replacement

The steel cable (1.2mm shift cable available in any bike shop) can be replaced as follows:

1. Remove the 4 screws and the back cover:

2. Remove the old cable and insert the new one:

3. Reinstall the back cover and the 4 screws(don’t overtighten to damage the threads in plastic):

The cable housing is 4mm shift cable housing available at any bike shop.

Kit Removal

It’s possible to remove this kit completely without leaving any marks. To remove warm up the tape with a heat gun (or hair dryer), then firmly and slowly pull the tape away from the surface. Use your fingers to remove the bulk of remaining of the tape on the metal surface, then wipe away the residue with Isopropyl alcool. That’s it!

The only permanent mark will be inside the latch mechanism (the plastic thingy drilled during the installation), but the 5/64″ hole left behind is almost invisible to the eye.

Shipping

wARRANTY, rETURNs & Refund

Warranty: If there is an issue with your handle (manufacturing defect, malfunction), we’ll be happy to send you another one free of charge! 🙂

Returns & Refund: You are responsible of shipping the product back to us (including the shipping fees associated with it) for the following reasons:

• Ordered by mistake or if you changed your mind.
• Incompatibility (see “Compatibility” section above).