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<!-- google_ad_section_start -->Drivers door lock replacement / Repair<!-- google_ad_section_end -->
Drivers door lock replacement / Repair
Published by Andy Monty
31-05-2010
Difficulty Level: 3

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Drivers door lock replacement / Repair

Well a regular complaint is the drivers door lock failing to open from the inside so here is how to replace and repair it


reasonably simple

you will need

a pozzi driver
a set of Torx drivers
a set of alan keys
an old towel
Duct tape
Stanley knife

and for teh repair
a dremel with a cutting wheel
and a couple of 2mm o-rings or a couple of washers to fit the shaft


Right first to get to the door lock the door card has to come off

pick the electric window switch panel out of the door with a flat screw driver in the slot
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next unhook the cable
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now remove the 4-5 pozzi screws at the bottom of the door card
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and the 3x socket cap Alan headed bolts (2 either side of the handle and one behind the door open pull catch ((under little cover that picks out))



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Now pull at the bottom corner and release up the sides (plastic push fit clips)

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put your old towel down to avoid scratching the door card

next lift the door card up slightly and unhook from the top of the door *(it hooks over)

and lower carefully

unhook the tweeter plug
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and the door catch cable nipple and remove
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followed by the outer cable retainer.
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that should now have the door card off


next cut an entry hole with a sharp knife or scissors at the upper left of the white door insulation foam/skin (in the area of the external door handle)

now you can get at the door lock unit..............

First un-clip the power cable multi plug pull the red tab down and this will release it
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now unhook the 2 control rods swing the retaining clip open then unhook the control rod..
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now get a torx driver and remove the 3 Torx retaining screws (near the door catch in the door edge)

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now remove the door lock mechanism

and cable by uncliping the retainer plate
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Now at this point you can fit your new door catch in reverse order....



However you "might" be able to repair it ((at your own risk)) its bust anyway but if you get it wrong you will not be able to lock/close your drivers door so check your local dealer has one in stock first and you have a willing chauffeur if its not in walking distance

Over time the metal release mechanism wears against the outer cover and slowly erodes it resulting in excessive play preventing the release mechanism catching on the door catch release blade

so first you have to get at it.... the door lock is held together by several torx screws and clips HOWEVER it is then clamped together by the metal clash/reinforcing plate.... preventing it been fully opened...

so this is where the dremal comes in

cut a slit as below:
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next remove the torx screw
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a bit more trimming round the door catch to break the hold and remove the section after unclipping the tab


now this is what area is worn
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so push the plate back and fit 2 o-rings onto the shaft this prevents the free play which prevents it from making contact with the release catch....
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and refit cover and refit to the car and cross your fingers .....
Thanks orange gp, deadduck thanked for this post
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Old 23-11-2010   #1
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Re: Drivers door lock replacement / Repair

Superb info, i cant thank you enough, removed the door mech and was just about to give up when i came across you thread . Followed it exactly what you said and it worked brilliantly, Honestly you have just saved me £50 . Thanks once again Briiiiiiiiiiiiiiiiiiiiiiiiiiliant
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Old 07-02-2011   #2
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Re: Drivers door lock replacement / Repair

Great explanation. Thank you. However, do you know the function of every wire of the connector? I would like to activate the door with an external alarm, other than the Fiat's original.
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Old 09-02-2011   #3
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Re: Drivers door lock replacement / Repair

superb how to mate!

was told the part was £45, then tried another dealership to see their price and was told that there have been 3 versions of the door latch, and they couldn't supply the older versions, but the latest version is £73!!

thankfully i came across you how to for the full repair and it's worked a treat today. there's some awkward parts and i had to superglue the plastic back together after being too heavy handed ha, but it was easy enough to do for a novice. can't thank you enough. you've saved me money
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Old 29-05-2011   #4
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Re: Drivers door lock replacement / Repair

Brill instructions, I did mine in 20 minutes. I was quoted £75 at Fiat but had a moan about the history of the part so I got a discount to £68. The 3 caphead bolts in my door were missing so I suspect it has been done before, which is worrying as it only had 4K on the clock when I bought it. Thanks for the info, it was invaluable.



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Old 06-09-2011   #5
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Re: Drivers door lock replacement / Repair

just chipping in, i had the exact same problem (wouldnt open from the inside only from outside) so i didnt bother taking anything off and compared the lock mechanism that i could see with the passenger side. i found that the problem was a metal lever n the drivers side which was connected to the inside handle had sprung above and on top of a plastic lever beneath it that it needed to push upwards when the handle is pulled. so just by using a screwdriver i rammed the metal lever back beneath the plastic lever (pulling on the outside handle made it easier to do this) and after a bit of effort i managed it! probably not helpful as its not tried and tested but just suggesting this to anyone reading this thread
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Old 16-03-2012   #6
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Re: Drivers door lock replacement / Repair

Quote Originally Posted by steaders View Post
just chipping in, i had the exact same problem (wouldnt open from the inside only from outside) so i didnt bother taking anything off and compared the lock mechanism that i could see with the passenger side. i found that the problem was a metal lever n the drivers side which was connected to the inside handle had sprung above and on top of a plastic lever beneath it that it needed to push upwards when the handle is pulled. so just by using a screwdriver i rammed the metal lever back beneath the plastic lever (pulling on the outside handle made it easier to do this) and after a bit of effort i managed it! probably not helpful as its not tried and tested but just suggesting this to anyone reading this thread
Thanks 'Steaders'...tried 'Andy Monty's' first to no avail but your simple solution worked...i owe you one m8.
thanks again and all the best...regards Mike in Cardiff.
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Old 26-03-2012   #7
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Re: Drivers door lock replacement / Repair

Steaders trick worked for me too after a bit of WD40 it made things way easier.
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Old 09-10-2012   #8
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Re: Drivers door lock replacement / Repair

I'd just like to say a big thank you to Andy Monty for posting this, along with everybody else who chipped in with further tips.

It has helped me immensely and after getting a new lock (£70 LC Motors Corporation Road Newport Gwent thank you ) it took me about 25 mins from start to finish.
I would like to add to Andys comment that this lock failure is a common complaint by saying, I had the same lock replaced 10 days after buying the car from new, under warranty in 2007.

Thanks Everyone

Ronnie
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Old 27-01-2013   #9
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Re: Drivers door lock replacement / Repair

Thankyou Andy M and Steaders for your advice. I have managed to fix the door myself by somewhat amaturely cracking open the case with a screwdriver (after undoing torx screw) and adding a washer from an old ikea set (those who dont have one, maybe use a washer from the lock mechanism torx screws). I think I understand the issue now and for the benefit of others I shall explain:



The metal on the right needs to lift the plastic up, but it was slipping due to Andy M's explanation above.
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Old 20-04-2013   #10
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Re: Drivers door lock replacement / Repair

Hi All , first post, a big thank you to Andy for his guide very helpful. Just thought I would let members know that a 5 door unit will work on a 3 door. I got my daughter a 2006 GP 1.2 Active and within 3 days the drivers door would not open from the inside, looked on Ebay loads of passenger door units. Got the old old one out of the car (51797566) went to the local breakers only had a 5 door GP took the unit out, looked identical (55797568) paid £20 I thought the electrical connector might be wired on different pins but I could take it back if it didn't work. Fitted it, works perfect including the remote locking. Great sturf !
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Old 18-08-2013   #11
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Re: Drivers door lock replacement / Repair

Another thanks to Andy for this procedure, very useful. Saved a lot of time, effort, and money. Note that these door locks are made in Germany. German engineering isn't always first class.
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Old 05-02-2014   #12
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Re: Drivers door lock replacement / Repair

Another fix after following this brilliant guide, steaders method fixed mine, oh the luxury of using my interior door handle
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Old 20-02-2014   #13
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Re: Drivers door lock replacement / Repair

Here is another vote for a great guide. Read it through prior to me tackling a replacement lock for an annoying rattle. A very easy job to do once I had read this guide. Many thanks.
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Old 14-03-2014   #14
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Re: Drivers door lock replacement / Repair

Thanks to those who contributed to this guide. I've just used it to fix the lock on my son's GP and it was really easy to follow. I've chosen to replace the mecahnism and it only took me about 30 mins. So cheers guys.
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