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<!-- google_ad_section_start -->The definitive guide to fixing a broken door lock.<!-- google_ad_section_end -->
The definitive guide to fixing a broken door lock.
Published by afroking
17-02-2009
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The definitive guide to fixing a broken door lock.

Step 1;
Take the lock out of the door by taking off the door panel and removing the 'U' shaped plate which wedges between the lock and outer door skin.

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Once you remove this plate, unclip the lever and pull the lock towards you from outside the car.

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When you have managed to get the lock out which can be fiddly you should be faced with this;

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Using a small flat headed screw driver prise the black outer casing from the barrel. Be careful as there is a small spring which will pop out if you are rough.

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When you separate the barrel from the plastic casing take the small screw driver and remove the locking clip from the barrel to separate yet another metal casing from the lock barrel. Lay the components out to familiarise yourself;

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You will notice at the end of the barrel there is a single prong, this is because the poor quality casting has caused the other prong to snap from general use.

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The next part gets tricky, you need to secure the lock barrel and drill directly where the prong has snapped. Be careful how deep you drill because you don't want to drill into the mechanism. Ensure you chose an appropriate sized drill bit which you can tap (thread) afterwards. I used a 3mm drill and tap. You should have something that looks like this;

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Next you need to find a screw and nut (3mm in my case). Ensure you use locktite on the threads and using the nut lock the screw into the end of the barrel like this;

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Cut the top of the screw level with the remaining prong.
The next problem you face on reassembly is the circular spring will not seat itself correctly because of the 3mm nut;

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Take a hacksaw and cut a relief in the nut, obviously not too near the thread of the screw as it will become loose. It should look like this;

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You can now reassemble the lock;

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All done!

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Make sure you test the lock at this point before re-fitting to save time later. You are now ready to re-install the lock back into the door. Remember to use both plastic washers and the 'U' plate when putting the lock back and last but not least remember to clip the lever arm on inside the door.

If you need any further advice feel free to PM me!

Good luck,

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Old 24-02-2009   #1
Join Date: Aug 2006
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Smile Re: The definitive guide to fixing a broken door lock.

Many Many thanks to Afroking for this post.

I've had a broken drivers door lock for quite some time (Fiat wanted to replace all barrels, keys etc) and it's a real pain having to lock the drivers door from inside the car all the time.

The only difference from the method described was that I used Araldite to secure the stud in the end of the inner lock barrel.

The worst part of the job, for me at least, was separating the lock from the rest of the mechanism in the door; the tiny ball joint is very tight. Also you need to be careful removing the "middle" barrel from the outer plastic sleeve to avid damaging the latter. Overall thou a very stisfactory and satisfying job. Thanks once again!

Best Wishes

Hugh
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Old 20-01-2010   #2
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Re: The definitive guide to fixing a broken door lock.

Hi, thanks for the guide. I just want to make this totally clear. For me, it is only the lock on the driver side that is faulty. I have a barchetta modell 1999. The thing is that the whole lock feels "loose" when i pull the key back and forwards and nothing happens. I can still lock it from inside and throw the centrallocker while looking the passanger door.

So it is not some electrical faught, I think it is something that have come loose from the lock inside, but I don't know how, hard to see, and havent gotten the time.

I'm just wondering, do you think this guide will sort out my problem??

I just don't wanna lock my car from the passengerdoor the whole time!
And it feels like a waste of time and money to take the car to a workshop for such a small problem.
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Old 20-01-2010   #3
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Re: The definitive guide to fixing a broken door lock.

Yes, it will solve your problem as one of the prongs has snapped inside.

Your lock is displaying the exact symptoms of a snapped prong.
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Old 20-01-2010   #4
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Re: The definitive guide to fixing a broken door lock.

Quote Originally Posted by afroking View Post
Yes, it will solve your problem as one of the prongs has snapped inside.

Your lock is displaying the exact symptoms of a snapped prong.

Ah great, thanks alot mate!! Will fix this annoying problem when spring comes to Sweden!
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Old 06-10-2018   #5
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Re: The definitive guide to fixing a broken door lock.

Thanks for the great guide! Just repaired my lock. I tried 3d printing a part to try to redistribute the rotation effort, but the PLA is not strong enough. So I did like you suggested and it works!
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