Disco 1 Front Door Lock barrel removal

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StuRox

StuRox

Well-Known Member
Posts
1,825
Location
Nr Bath
Need to some help/advice on how to change the lock barrel on the front drivers door lock of a 1995 300 tdi.

Handle was broke on the doer-upper I have got, so managed to get another one and was told you just switch the barrel to keep using the same key….easy!!!

Well, after stripping it out, I cannot seem to get the barrel out. It looks like it comes out of the handle, but the metal levers on the rear won’t come over the lip of the barrel…..
normal_20160513_134754.jpg


normal_20160513_134733.jpg

Am I doing something very wrong, or is it a case the barrels don’t come out??
 
To the rear (opposite end) where you red arrows are pointing should be a small 'C' clip that you will need to prise off with a screwdriver. Once you've done that put the key into the lock (this aligns the tumblers) then the inner barrel & tumblers should come out all in one. When you take out the key be very careful as the wafers and tiny little springs will fly off into the eather and you'll never find them again.

I've just done something similar with my Disco, I had 3 different keys for 4 locks, so instead of replacing all / some of the locks, I reset the existing locks wafers to match 1 key, fiddley, bit frustrating but satisfying once its done. :D
 
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Is the C-Clip the part of the barrel that the right arrow is touching - I thought it was part of the barrel, but might have corroded over time to look like part of the barrel, as I couldn't see any other clip????
 
From looking at that photo it does look like the 'C' clip I mean, if you get a screwdriver (or 2) one either side & push or tap it away it should pop off.
 
ok, cool. will try that when I get home, as didn't want to pry and bash it too much in case I messed up the barrel :eek:
 
I'd keep the old tumbler as a spare but as I said before be very careful when you take the key out of the lock as the wafers are spring loaded and WILL fly off along with the tiny little springs. (I took the key out in a plastic bag so I could catch everything). You can by swapping the wafers around make it fit your existing key & then you'll have a cleaned up spare ready on the shelf.
 
Will it be a problem to get the barrel out on the new handle I got, as I don't have a key for that one??
 
Yes, you need to put the correct key into the barrel to line up the wafers correctly inside (from memory) otherwise it won't come out.
 
All done, thanks guys for the help - easy when you know how!

normal_20160513_172905.jpg


It was a c-clip that had over time got a load of crud on it making it look like part of the metal!

Also, the barrel comes out without a key, so I can now play around with the barrel to make it work with the keys I have, as per the above video so I have a spare.
 
Hi all I am having problems with my Disco 1 lock. I have it out but the person who tried to steal my car broke off something in the lock barrel. I have removed the circlip and find that as you say the barrel still does not want to come out. Any suggestions appreciated. Cheers Steve
 
Hi Steve,

You need to put the correct key into the barrel to line up the wafers correctly inside (from memory) otherwise it won't come out, once they are aligned it should just slide out.

Have a quick look at the tutorial in reply #10 from about 1min 50 onwards.

I don't know what damage has been done when the delightful little $***t tried to steal your car but if they inserted a screwdriver into the key slot and forced it, they may have damaged some of the little wafers inside the barrel, thus why it won't just slide out
 
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Hi, WellI have spent a couple of hours and have finally removed the bit of broken scissor!.I think you are right and a couple of the wafers are damaged. I will buy a new barrel and re key as per your you tube feed. Thanks for your help, at least I won't have to unlock the passenger side and climb across. Just need to get the lock to undo the other doors at the same time. Cheers Steve
 
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