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D2 - Common Faults Quick links to all known common faults and their solutions |
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Thread Tools | Display Modes |
#1
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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.
------------------------------------------------------------------ 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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2001 A8 D2 FL 3.7 Q - LPG Conversion, Engine: AKC, Gearbox:FBB, Colour:LY5X Aqua Blue pearl effect, Interior:WJ light beige/dark beige valcona leather with burr walnut inserts 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 Sold! 2008 S8 D3 5.2 V10 - Engine: BSM, Gearbox:KLW, Colour:LY7F Suzuka Grey Pearl Effect, Interior:Black/Black with Silver/Black valcona leather with carbon atlas inserts, Bang & Olufsen, Heated windscreen, Soft-close doors, TV, DAB, AMI, Quad Zone, Auto Boot, Auto dim Mirrors, Keyless entry, PDC with rearview camera, AFS II Headlights My DIY jobs - Fan Jet Windscreen Washers, Retrofitted Electric Side Blinds |
#2
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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 |
#3
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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. |
#4
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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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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 - nope, definitely not - horrible botch!). |
#5
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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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#6
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The printed part is perfect for the job will post a pic later
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#7
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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 - nope, definitely not - horrible botch!). |
#8
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Printed seal in place:
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#9
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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!!
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2002 D2 S8 – Ming Blue, Valcona leather, Vavona wood insert, solar sunroof (to be fitted), Heated rear seats, extended leather pack, 18” Avus, ski hatch, Bose, auto dim rear view mirror, rear blind. |
#10
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The solution is cheap as chips for missing rings.... http://forum.a8parts.co.uk/showthread.php?t=15821
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.). 2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one! Finally: gone, but not forgotten..... 1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors. e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later) 1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer. And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850! |
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