Date: Wed, 6 Nov 1996 12:36:15 -0500 (EST)
Sender: Vanagon Mailing List <vanagon@vanagon.com>
From: ERIC ZENO <emz@viper.nauticom.net>
Subject: Mod. of door lock
Rework of drivers door lock: allows locking of the door without key
I have make this modification. on 3 locks. 2 of witch are from 1986
models, and 1 on a 1980 model. (this may explain why VW did what
they did) In the 86's, as you exit the inside, you must unlock
the door, to get out. With the 1980 model, after the mod., you can
exit, regardless of weather the door is locked or not. This means
it's even easier to lock your keys in the car! so:
Step 1 - Make sure you no where your wife is at all times or
if you don't have that headache, hide a key on the outside
of the vehicle.
Step 2 - Remove the door lock: 1 small screw barried in the rubber
holds the outside handle on, 2 larger screws hold the lock
to the door. 2 levers- the inside lock lever, and the
inside lock handle.
Step 3 - After removal clean the old grease and dirt out.
Now you can see whats going on. At the top/inside you
will see a lever that pivits on a large rivet with the
lock in the opened position only. This is also
the piece that connects to the inside lock lever. This is the
part that needs to be modified. Work the lever with the
lock opened and closed, and note the bent over tab at the
very top that stops the inside lock lever from moving, in
the opened position.
Step 4 - Cut off the tab: This is the hard part. In the 1980 lock I
have removed this part to made the mod. In the newer style
removal seams impossible. If you have a Dremel
tool or a die grinder with good bits and alot of time,
you can make the mod., without removal. Maybe someone
can find a way to remove the newer style. To get
this part out of the older style, you must cut the
rivet head out. Cut the rivet head off of the inside with
eather a die grinder, a milling machine or a drill. There
is a flat washer over the rivet and 2 springs connected to
the lever that you must keep track of. It's a puzzle to
remove and install, but it can be done. Grind the tab off
using a a bench grinder.
Step 5 - Install in reverse order! That's what it always saids! The
only hard part is what to do about the rivet. The last one
I did, I had a friend, (after fussing with it for about
10 minutes) spot weld the washer to the remaining end of
the rivet. There maybe another way. If you use a milling
machine to remove the head of the rivet, you maybe able to
drill and tap the rivet. This would be the best solution.
Step 6 - After installation grease the lock well. Make sure it works
and reinstall. Note after the lock is installed on the door
there was a small amount of silicone seal between the bottom
of the lock and the door.
Have Fun
Eric Zeno <emz@nauticom.net>
86 Syncronizer
86 GL For Sale (Pgh. PA)
72 240Z 1936 Chrysler