Rebuilt the front passenger side lock again. I cleaned/lubed the motor in 2017, so this time I replaced the motor with a new one. Turns out the old motor has a knurled spline on the shaft to retain the gear so I used a bit of red loctite to put the gear on the new motor. Should have just popped the end bell off and cleaned it up again I suppose.
Last time I disconnected the cables to the outer handle and cylinder. This time I thought I'd remove the handle and lock as a unit. Getting it out was easy, but there is a steel shield around the cylinder and it took me the best part of an hour to wiggle it back into place with the shield fitted. Next time I'll disconnect the cables again or just leave the shield off.
Drivers rear can wait until the weekend. At least that one locks and unlocks most of the time.
Edit:
After examining the motor I pulled out, it's toast with a capital 'F'. The brushes are completely gone and the commutator is well and truly stuffed, so there was no way it was going to be remediated a second time. I bought a new set of main lock motors from Amazon back in 2017, but as I discovered today the originals had a knurled shaft. That got me looking based on the part numbers of the one I removed, and I stumbled across this : For Land Rover door lock motor for Freelander 2 Range Rover sports version found 34 Aurora lock motor worm|Cables, Adapters & Sockets| - AliExpress
Both motors, with what appear to be the correct pinions already in place. So I've ordered 4 of each and we'll see how well they fit when the next one gives up.
