What are my options here?(Sliding door roller mount rust-out

[Quihyp]

The upper roller for my sliding door was worn out so I went to replace it with a salvage one but when I took the original off I found that there's no way to attach the new one. As you can see in the picture, the holes where it should mount have corroded away (how is a mystery to me, as the rest of the van is basically rust-free). When removing the old one I heard an audible clunking which I now know to be nuts or somesuch used to clamp the old one one, but how did they manage those in the most impossible-to-get to corner of the door?

Basically before I go pull a door and inevitably make a post about how I can't figure that out, what are my options here? Has anyone encountered this before? I assume that any welding or additive metal will mess up the alignment of the door.

[CaptSquid]

There are products called RivNuts. Basically, they are blind nuts installed much the same as pop rivets.

On the less labor intensive side, I'd suggest just replacing the entire sliding door.

[WoodButcher]

On the less labor intensive side, I'd suggest just replacing the entire sliding door.

+1

[Smiliesafari]

Can't help but wonder how much rust is in the rest of the door. It looks like it would be more cost effective to just replace the door. That's good advise from the rest of the guys.

[Quihyp]

Can't help but wonder how much rust is in the rest of the door. It looks like it would be more cost effective to just replace the door. That's good advise from the rest of the guys.

The van pretty rust-free so this came as a huge surprise to me, especially for it to be in such a weird and critical place. Anyway I'll start combing for pick-a-part doors tomorrow when they put the new ones out. Will a slider from a passenger fit on my cargo van? I'd like one with a window that opens.

[1Gary]

http://www.car-part.com

[okie1]

I doubt rust was your problem, looks like metal fatigue. Things were not tight which enabled the metal to flex and eventually break. Looks for sure a new door is in order.

[1Gary]

A bit more work to do,but you get the suggestion.


http://i172.photobucket.com/albums/w33/ ... step-1.jpg

[1Gary]

[WoodButcher]

Will a slider from a passenger fit on my cargo van? I'd like one with a window that opens.

Yes, I did that to my '97 work van for just that reason. The airflow at the end of a hot summer day is heaven...

[doyoulikeithere]

the doors on these vans are pretty much universal as far as physical fit goes.
You should be able to use any slider door from any year or style of astrosafari van.
Same goes for the 2 front doors.

Of course, as I mentioned, this is the physical fit.
electrical Plug ins for accessories like power windows door-locks mirrors etc are up to you to mod for fit, if necessary.

Good Luck, change to another slider is the easy way to go there....

[1Gary]

The striker locations are different.They changed after 1997.

[doyoulikeithere]

The striker locations are different.They changed after 1997.

Really !!??!!??
OOPS.
I stand corrected then.
I gotta remember all the time that all my vans were pre 96.....