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-   -   Boot Lock Failure - Removal and Repair (http://forum.a8parts.co.uk/showthread.php?t=16132)

steamship 16th February 2021 09:49 AM

Boot Lock Failure - Removal and Repair
 
The following instructions on the repair of the boot lid locking mechanism is the work of Michaela/MikkiJayne/D2 Doctor and is a single post extract from one of her threads. I've posted it as a separate thread to make it easier to find.

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Also fixed the boot lock since it was seized completely solid

Removed via the door for for the light cluster

http://forum.a8parts.co.uk/attachmen...1&d=1524342355

Disassembled the main body

http://forum.a8parts.co.uk/attachmen...1&d=1524342355

http://forum.a8parts.co.uk/attachmen...1&d=1524342355

http://forum.a8parts.co.uk/attachmen...1&d=1524342355

The lock barrel was completely seized in the housing. Lots of WD40 and wiggling and it finally came free.

http://forum.a8parts.co.uk/attachmen...1&d=1524342355

Crusty!

http://forum.a8parts.co.uk/attachmen...1&d=1524342355

Started removing the tumblers

http://forum.a8parts.co.uk/attachmen...1&d=1524342355

http://forum.a8parts.co.uk/attachmen...1&d=1524342355

All disassembled. It took about half an hour cleaning schmutz out of the barrel with an assortment of pokey tools, degreaser and compressed air before the little door would close again!

http://forum.a8parts.co.uk/attachmen...1&d=1524342355

Cleaned all the tumblers up

http://forum.a8parts.co.uk/attachmen...1&d=1524342355

Reassembled prior to re-greasing

http://forum.a8parts.co.uk/attachmen...1&d=1524342397

Going back together

http://forum.a8parts.co.uk/attachmen...1&d=1524342397

http://forum.a8parts.co.uk/attachmen...1&d=1524342397

http://forum.a8parts.co.uk/attachmen...1&d=1524342397

You can see the cam which operates the central locking here via these two microswitches

http://forum.a8parts.co.uk/attachmen...1&d=1524342397

All back together and ready to put back in

http://forum.a8parts.co.uk/attachmen...1&d=1524342397

MikkiJayne 16th February 2021 10:02 AM

Thanks Sean +++

Refreshing my memory on how this goes together, I think the key just spinning may be caused by the tab on the end of the lock barrel not being engaged properly in the rest of the mechanism. Given that this whole thing is mostly lightweight pot-metal it could be that one or more pieces are actually broken, but if that is the case then either the barrel, or the individual tumblers could be swapped in to a used lock mechanism to resolve the problem while keeping the same key.

If anyone wants to remove a spinning lock and send it down for diagnosis / repair then let me know :)

MikkiJayne 21st February 2021 09:56 PM

4 Attachment(s)
I've been having a look at David's lock over the weekend. Everything seemed in good order and nicely greased, but the barrel was stuck fast in the surround. After sitting overnight in WD40 I managed to get it apart and discovered that it was just corrosion on the first few mm of the barrel holding it place.

http://forum.a8parts.co.uk/attachmen...1&d=1613947807

After cleaning, it was clear why - the rubber seal was perished and disintegrated so moisture could get in.

http://forum.a8parts.co.uk/attachmen...1&d=1613947807

The seal is a flat-ish moulded thing which is not available as a spare part. The thought occurred that an o-ring might work to replace it, and the oil cooler pipe o-ring appears to be just the right size

http://forum.a8parts.co.uk/attachmen...1&d=1613947807

It actually goes together quite well, but its a little stiff to turn so it might need a smaller o-ring.

http://forum.a8parts.co.uk/attachmen...1&d=1613947807

Or, I might see if I can print a polyurethane replacement for the original seal.

The_Laird 22nd February 2021 10:49 AM

Mine doesn’t have a seal there at all, and the barrel was corroded at the top end like David’s. I’ve got a load of different sized O-rings, so I’ll pop one in when I fit the last tumbler. Good job you pointed that out, otherwise I expect mine would have corroded again in no time!

MikkiJayne 22nd February 2021 11:09 AM

I'm about to try printing one. If it works, I'll post you one with the tiny spring which will be on its way this afternoon :)

MikkiJayne 22nd February 2021 12:11 PM

The printed part is perfect for the job +++ will post a pic later

The_Laird 22nd February 2021 12:28 PM

You’re a star! Thanks Michaela

MikkiJayne 23rd February 2021 08:30 AM

1 Attachment(s)
Printed seal in place:

http://forum.a8parts.co.uk/attachmen...1&d=1614072544

David's8 23rd February 2021 08:37 AM

Thanks MJ, +++
Neat job .... and now youve shamed me with the state of the key (its lost the audi rings and generally looks old and battered like its owner), im going to have to get a new key!!

HPsauce 23rd February 2021 08:56 AM

The solution is cheap as chips for missing rings.... http://forum.a8parts.co.uk/showthread.php?t=15821


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