Boot Lock Failure - Removal and Repair

[steamship]

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

[MikkiJayne]

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]

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.

[The_Laird]

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]

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]

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

[The_Laird]

You’re a star! Thanks Michaela