Author Topic: Driver's door lock barrel badly worn. Options to fix it are...?  (Read 4625 times)

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Driver's door lock barrel badly worn. Options to fix it are...?
« on: November 13, 2011, 13:47:59 PM »
My driver's door lock barrel is badly worn. It onlys locks on the 90 degree deadlock position. The normal 45 degree lock position doesnt work, and the window close function don't work either. When locked, the key hole position sits wonky (ie instead of being flat, it sits at an angle of about 20 degrees. So basically i need to do something to fix it.

As i see it i've got two options

1. The simple option - swap the drivers lock with the passenger lock
2. The advanced option - i've read you can get any other barrel dismantle it, and rearrange the tumblers (anyone done this?)

My first problem is i can't see how to remove the barrel from its metal backing plate? I've got a pair of mole grips around the barrel, and whilst there is about 1mm of play (ie there is movement) the barrel doesn't turn so i can remove it. Am i missing something?

Tips and suggestions welcome!!!

Pics of the barrel and plate





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Offline sealeysonic

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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #1 on: November 13, 2011, 14:15:05 PM »
Option 3....maybe fit remote locking...? just a thought mate.

Offline Butcher

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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #2 on: November 13, 2011, 15:47:37 PM »
Looks to me like there's a pin or grub screw holding the barrel from turning on the first pic left hand side of the barrel, will that pull/screw out allowing you to turn the barrel and remove?

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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #3 on: November 13, 2011, 19:08:47 PM »
Option 3....maybe fit remote locking...? just a thought mate.

This is my 'best' cally, so i'd rather fix it than workaround it ;)

Looks to me like there's a pin or grub screw holding the barrel from turning on the first pic left hand side of the barrel, will that pull/screw out allowing you to turn the barrel and remove?

Yes there's a pin/rivet bit on one of the arms(?), however, if you look at the direction the barrel needs to turn to remove it, its in the opposite direction to where that rivet is. So at the moment, i can't see what that rivet actually does. It doesn't seem to be the bit stopping me from turning the barrel with the mole grips, and that's where i've got stuck!
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Offline john wollaston

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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #4 on: November 13, 2011, 19:26:57 PM »
hi mate i have had these apart before on several vauxhalls you will have to tap or pull out that little pin type thing you will then be able to twist the rest of the asssembly out like u were trying to. good luck

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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #5 on: November 13, 2011, 19:48:54 PM »
Have it de-locked...

Why don't the 'Additional Options' give me the opportunity to add an image at this point..?

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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #6 on: November 13, 2011, 20:08:26 PM »
Have it de-locked...

I considered that, as well as the remote central locking option, but this is our 'best' 50k miles Cally, and i'd rather go down the 'keeping it original' route if possible on this one.

I'll try to get that pin/rivet out as suggested by John. I can only imagine that pin goes all the way through, and out the other side, and then into some sort of indent to be holding it in place.

How did you get the pin out John? I can't see it would tap out, as you can't get to the back of of it, but assume maybe it pulls out with a pair of mole grips etc. Will have a look and report back!
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Offline john wollaston

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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #7 on: November 13, 2011, 20:20:47 PM »
sorry yes i meant to say i pulled it out with a pair of long nosed pliers, mole grips are a little big, then i got a hammer and a flat head screw driver and tapped the other piece round untill it came out.

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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #8 on: November 13, 2011, 20:37:56 PM »
sorry yes i meant to say i pulled it out with a pair of long nosed pliers, mole grips are a little big, then i got a hammer and a flat head screw driver and tapped the other piece round untill it came out.

Result. Just got a pair of mole grips on that pin, and it pulled straight out. It is indeed pushed into a little indented bit on the other side, that holds it in place.

I then used the molegrips to turn the barrel and it came straight out :)

This was the passenger lock i've just done, as i happened to be working on that door anyway, so i'll do the drivers door lock later in the week when i get time.

At least i can swap the passenger and driver lock barrels over now, assuming there is nothing different about them?

When i get the driver's side barrel out, i'll have a look at this rearranging tumblers thing, as i've got a couple of old lock's from a scrapper, that i might be able to make a new lock out of.

Has anyone had a go at doing this before?
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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #9 on: November 13, 2011, 21:20:57 PM »
I considered that, as well as the remote central locking option, but this is our 'best' 50k miles Cally, and i'd rather go down the 'keeping it original' route if possible on this one.
Fair enough.  I can understand the desire to keep it original.  One of my reasons for going for delocking was that it means there isn't a barrel-lock for some little toe-rag to come along and hammer a screw-driver in to to break into the car.

Offline john wollaston

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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #10 on: November 13, 2011, 23:16:42 PM »
let us no how you get on glad you got it apart in the end, if i remember rightly i had the same problem on a mk3 astra once with the lock not working properly, dont quote me on this but i think there is a spring in the lock assembly and on top there is a little metal plate then a circlip which holds it all together, what was stopping this one from working properly was that the spring over the years had  become so compressed it was not pushing enough pressure against the plate so when you turned the key the mechanism was slipping past to far rather than engaging, i just got a new spring from vauxhall and job was a gooden!!  :D

Offline Gordo

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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #11 on: November 14, 2011, 13:43:45 PM »
Any decent locksmith should be able to set a new lock up to match the old pin setup - a bit of hassle but means not needing two sets of keys.

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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #12 on: November 14, 2011, 14:12:33 PM »
Any decent locksmith should be able to set a new lock up to match the old pin setup - a bit of hassle but means not needing two sets of keys.

For what needs doing, i'd rather have a go (and learn) myself how to do it rather than pay someone else to do it.

Sounds a bit scary, regarding the care that needs to be taken when taking apart, and the small springs to watch out for etc, but i've only got to do it on a lock that's already knackered anyway! ;)
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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #13 on: November 23, 2011, 16:20:40 PM »
Made some progress on this. Got the drivers side lock out and found the main source of my problems, the deadlock casting had broken off and was rolling around inside the door. Looks like a common problem (a design fault) according to the various vauxhall forums.

It took me a while to find all the information i needed from various sources, so i'll collate it here, as another resource for people to find.

Here's a pic of the broken deadlock part (taken from another forum). On the left is the part broken in exactly the same way as mine, on the right is how it should look when not broken. When this piece breaks, the symptoms are that you have no 45 degree lock position. Only the 90 degree lock position works, but only as far as the basic locking of doors, it doesn't apply the deadlocks as it normally does in that position:



The part in question is as follows from the EPC:
14 = 90540614 = Dog, Lock Barrel

However, it appears the recommendation is to get all 3 of the following parts when fixing this:

13 = 90540616 = Lever, Assembly, Lock Barrel Dog (?11.40 + VAT)
14 = 90540614 = Dog, Lock Barrel (?3.86 + VAT)
15 = 9120412 = Roller, Lock Barrel Dog (?1.68 + VAT)

Here's a few relevant forum threads on the subject

http://www.clubcalibra.com/technical-troubleshooting-servicing/found-out-why-my-deadlock-and-alarm-doesn%27t-work/
http://www.opelaus.com/forums/showthread.php?4279-Need-some-urgent-help-from-anyone-that-can-and-is-willing!

http://www.migweb.co.uk/forums/other-mechanical-electrical/163143-weird-central-locking-deadlocking-problem.html

http://www.corsasport.co.uk/board/viewthread.php?tid=408874

and here's a blow up diagram of the drivers side handle and lock mechanism. Note the part numbers don't match up with those I posted above. I think the part numbers above are numbered 21,22 and 27 on this diagram


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Re: Driver's door lock barrel badly worn. Options to fix it are...?
« Reply #14 on: November 23, 2011, 16:25:48 PM »
Just to add, I ordered the three parts needed from Autovaux which came to ?26.48 delivered.

For info, they had to outsource this order to a dealer as they didn't have them in stock themselves.

Currently awaiting delivery. Will update again when they arrive.
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