Date:         Mon, 6 Aug 2007 22:30:13 -0400
Reply-To:     Kim Brennan <kimbrennan@MAC.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Kim Brennan <kimbrennan@MAC.COM>
Subject:      Locks
Content-Type: text/plain; charset=US-ASCII; delsp=yes; format=flowed

When I bought my 91 non-GL syncro, the drivers side door would not
lock with the key. The other doors (and hatch) worked fine. I figured
it might be a replacement door based on the nicks and bangs on the
rest of the vehicle. But the more I drove it, the more it seemed more
likely to be crud, rather than a different door lock.

So tonight I took it off (2 minutes to get the handle off, with lock
mechanism.)  I used brake cleaner to first take a chance at cleaning
things up. No luck (oh, it got a lot of junk off, but the lock still
didn't work with they key.) So it was disassemble the mechanism time.
The lock is held in with a drift pin. Fortunately I had the requisite
punch in that size (it's fairly small). Knock out the pin most of the
way (to clear the shaft, but not come completely out of the lever
arms.) Remove lever arms. The lock mechanism comes out the front of
the handle.

Junk. Oh, I'm sorry. GUNK. I think a previous owner or shop had used
just about every lubricant known to work on this. It looked like
grease, teflon and graphite was all congealed into an impenetrable
mess. Add in NY road salt to tarnish the brass keys and you've some
idea of the issue. Essentially, things were so gunked up that the
keys couldn't move. I had to use a punch to get them free of the
cylinder.

Then it was cleaning time. More brake cleaner on the cylinder (being
painfully careful to not wash away the springs that are in there.) I
used steel wool on the brass keys (being careful to note the order
they were in. More steel wool on the outside of the cylinder. Brake
cleaner on the handle where the cylinder fit (used a flat screwdriver
first to get the gobs of congealed bacon grease, or whatever it was
out of the handle.)

Finally with things cleaner (not like new. This was a quick and dirty
fix). I reassembled (well, I picked up the brass keys that jumped out
a couple of times.) Finally I inserted the car keys and saw that this
handle did indeed work with the original keys.

I then put it back on the Van. Nice to have a van with working door
locks again (now the thieves have to break a window to get in.)