 Exterior Door Handle Stops
I recently replaced the tumblers in my driver's side door lock cylinder, and when I reinstalled the handle assembly, I noticed that the handle was not flush with the trim surrounding it, sitting noticeably lower. Further inspection revealed that the rubber stops were missing. Having several handle assemblies, I appropriated the only stop still present and installed it in the handle assembly on the vehicle. Being damaged, it wouldn't stay in place, so I set off to find a replacement. Realoem lists the PN as 51211970863, available from many sources, but at a price - roughly $10 each. I set off to the hardware store in search of something workable, or something that could be suitably modified. The picture shows the original part on the right, made of soft rubber. The part on the left is Hillman PN 4804-A, Automotive Panel Fastener, 1/16-3/16 panel range, 7/64 hole, $0.40 at my local Ace Hardware.
To install the original part, you need to access the inside of the door to pull the "tail" of the rubber through the mounting hole; to install the Hillman part, you only need access from the outside. I've included a picture that shows the part where it sits in the handle assembly. To install, position the part with needle nose pliers and use the door handle itself to seat it. The Hillman part is hard plastic, and so the feel and sound may be a bit different when you release the handle, but it now sits pretty much flush with the trim.
Paul
'96ti 222,500mi | 
Linear Mode
