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Date:         Sun, 27 Oct 96 10:11 CST
Sender:       Vanagon Mailing List <vanagon@vanagon.com>
From:         EF0JPB1@mvs.cso.niu.edu
Subject:      Re: Door Handle Repairs

Evidently my post on door handles and locks struck a nerve. wsilva@capecod.net was correctly informed that VW used a grease. Ric Golden's suggestion to use penetrating oil instead of WD40 will work on locks not *terribly* gunked up. Once crud develops inside the core, a lot of cleaning is in order.

I now have two of the three offenders fixed. As I stated in my previous post, I discovered the core for the two front doors is held in place by a dowel-pin (VW terminology for tension pin at Ace Hardware). I could not drive the pin out and resorted to force. Since I couldn't find a 2mm pin, I settled on a 1/16th inch cotter pin (stainless) and drilled out the old pin very carefully.

After the core is removed from the handle it's a matter of removing all crud so things operate smoothly again. I pulled all seven tumbler wafers (keeping track of the order) out and used Brasso to bring back the shine. I pulled all seven tumbler springs and cleaned them too. These are tiny! It helps to run a straight pin or safety pin through them to keep track of them while you clean out the gunk. I used a tootbrush. While extracting one spring it shot across the room, so be careful! Fortunately this is one part from a split-window bus which will fit a Vanagon and I have extras from a '67 ignition switch.

While VW used a grease, I found that most of the crud I removed was graphite/grease combo (from putting lockthaw in I'm sure). After a while the springs get filled up and won't *spring* anymore. Then the tumbler wafers won't move and get stuck in the "open" position. I just read Tim Smith's post and agree totally with his approach, though I used carb cleaner and compressed air to clean the barrel.

One more thing...there's a nylon (I think) washer that slips over the barrel when it goes back into the handle. Old buses used O-rings and/or a felt ring to keep water and other contaminants out of the lock. My opinion is that what we put in is probably the worst offender, not nature, so be careful what you squirt in the keyhole, you'll either have to live with it or eventually clean it out!

This is one of those projects that doesn't fit well in the "automotive repair" category. The "car guys" generally don't work on locks. The "lock guys" aren't interested in the van much either. If you need lock repair, I suggest you remove the handle yourself. We're all handy aren't we? If the lock repair is beyond you, take the handle(s) to a locksmith and let him/her do the "fine" work.

-Jim Bryant


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