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D2 - Common Faults Quick links to all known common faults and their solutions

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Old 16th February 2021, 09:49 AM
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steamship steamship is offline
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Default 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



Disassembled the main body







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



Crusty!



Started removing the tumblers





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!



Cleaned all the tumblers up



Reassembled prior to re-greasing



Going back together







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



All back together and ready to put back in

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My DIY jobs - Replaced alarm horn, Replaced Coolant Temp sensor, Updated RNS-D firmware, Installed Reversing Camera and Digital TV, Dashcam Installation, Retrofitted Rear Blinds, Auto-Dimming Rear View Mirror, Chrome Boot Struts

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Old 16th February 2021, 10:02 AM
MikkiJayne MikkiJayne is offline
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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
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Old 21st February 2021, 09:56 PM
MikkiJayne MikkiJayne is offline
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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.



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



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



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



Or, I might see if I can print a polyurethane replacement for the original seal.
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Old 22nd February 2021, 10:49 AM
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The_Laird The_Laird is offline
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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!
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Current mods: solar sun roof, 20mm rear spacers, 15 mm on front, red brembo callipers, 6k headlights, rear view camera, engine remap, alloy dash dial rings, alloy navi rings, tt/phaeton pedal upgrade, (and custom matching foot rest) dension ipod interface & parrot hands free kit (both fully hidden), av input, tv in motion switched thro' PF switch in blanking plug right of steering column, Audi 'quattro' sill covers, repositioned centre console switches, radio clock, .
Planned mods: auto-dimming rear view mirror, dash cam (as steamship's), fit the ski hatch, refit philips drl's (or maybe not).
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Old 22nd February 2021, 11:09 AM
MikkiJayne MikkiJayne is offline
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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
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Old 22nd February 2021, 12:11 PM
MikkiJayne MikkiJayne is offline
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The printed part is perfect for the job will post a pic later
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Old 22nd February 2021, 12:28 PM
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The_Laird The_Laird is offline
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You’re a star! Thanks Michaela
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2002 Final Edition S8. Ebony black with Silver Grey leather and myrtle wood trim.
Current mods: solar sun roof, 20mm rear spacers, 15 mm on front, red brembo callipers, 6k headlights, rear view camera, engine remap, alloy dash dial rings, alloy navi rings, tt/phaeton pedal upgrade, (and custom matching foot rest) dension ipod interface & parrot hands free kit (both fully hidden), av input, tv in motion switched thro' PF switch in blanking plug right of steering column, Audi 'quattro' sill covers, repositioned centre console switches, radio clock, .
Planned mods: auto-dimming rear view mirror, dash cam (as steamship's), fit the ski hatch, refit philips drl's (or maybe not).
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