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When I sent my 1954 exterior door handles off to be re-chromed, I removed the thumb button mechanisms. The mechanism is held in by two tabs that lock into holes in the door handle casting. I used a punch to push the tabs out of their holes and forced the mechanism out but it was not an easy task.

Is there a better way to put these back in than just forcing them into the door handle? Should I try to straighten out the tabs and if I do, how would I bend them out again so they lock in the holes?

One of my handles already has a crack in the casting where the mechanism slides in and I am worried about breaking a piece off if I try to force the tabs into position.

I'm hoping someone will answer as I'm curious too. Whenever I've tried to remove the buttons as you did, the little tabs end up breaking off!

There are probably many methods and others that may be easier but this one works for me. It may not be Packard approved and could void the warranty so be forewarned.

I find it less of a hassle working with the retainer by getting the spring completely out of the way when trying to manipulate the tabs into the holes. To hold the spring I make a holder out of baling wire or a strong paper clip to compress the spring and then tape the holder to the handle making sure it is positioned in the longer slot. That keeps the spring well down and away from the action.

Once the spring is compressed, start the retainer at a steep angle taking advantage of the bend in the rod for extra room for the tilt. Work it down until one tab is in a hole. It will take some effort and be sure the tab stays lined up with the hole as you work it down. Once one tab is in position that provides a bit more room so using screwdrivers or whatever start the other side of the retainer down. The retainer edge still up will want to catch on the handle edge so needs to be guided and maybe compressed slightly. The slot in the retainer will allow a small bit of compression. Push the retainer the rest of the way down until the other tab slips in the hole. You can then remove the holder by cutting or whatever.

If one side of the spring works out of the retainer when removing the holder you can push down on the side of the spring still in the retainer to lessen the diameter and provide room to push the errant side back in.

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Thanks a lot Howard. The pictures were really helpful.

Are replacement springs available? My door pushbutton doesn't want to pop back out even the I've cleaned & oiled the assembly.

Have you tried your local hardware store? Mine had an assortment, one of which worked perfectly, just requiring a trim to length.

Any chance the pot metal in the handle has swelled or perhaps the stainless cover over the button pot metal or the pin holding the rod to the button has worked loose and is dragging in the housing.

For what it is worth the spring part number is 435214. Max doesn't list them but you might see if Kanter has any NOS and surely there are used from parts cars around. If not, it is a common compression spring and by matching measurements the identical or something similar that would work could probably be found locally or at McMaster-Carr or MSC.