Thread: Sensational D2 Drivers Door Lock Replacement

I thought I could live without it, but not being able to unlock your drivers side door is pretty darned annoying boys and girls! So.... Step 1. Go earn $200 to buy a new one because the old Series 2 Disco Door lock actuator mechanism is a single unit consisting of the door lock and the actuator mechanism. Made in Germany which helps NOT AT ALL!

Step 1 remove the door trim, bust a whole lot of the little plastic clips and make sure you have about a half dozen new ones ready to go.





STEP 2

The mechanism is tucked in pretty deep.



And also jammed in by the window track. You're gonna feel the pain here becuase you need to shove your arm right up the door to play.



STEP 3
undo the Torx bolts holding the actuator into the door. They are the lower ones there on the jam side of the door and there's also a small black screw on the inside fascia hidden by the plastic lining.



But don't do anything with it yet.

STEP 4


See all those levers, you're gonna have to have faith here people because initially you will not believe that any of them are accessable by the human hand. But for the external door handle actuator lever thingy, it goes vertically up on the top left of the pic, I disconected it from the door handle, to do this pop the little plastic retainer off the top hooked part of shaft, rotate it away and disconect the shaft, leaving the plastic retainer in there and leave the shaft attached to the actuator. That green lug in the pic is the door lock button, it just pops off. and the goldy looking hook at the bottom of the actuator is the internal handle. Just un hook that and let it hang. The Key lock shaft runs horizontally across from the key lock to a hiddn hole in the top of the actuator. Undo the small torx screw, push the external handle assembly backwards and it should come free of the door. It's kind of spring loaded.

STEP 5
Now see in the above image how the actuator is TRAPPED by the windo slide.... Well don't panic as I did. All you have to do is remove the two Torx screws - one on the slam side and one on the hinge slde that hold the channel in and also remove the two bolts holding the bottom of the channel...


And there's another bolt on the inside face of the door up near the the top left corner, kind of hidden, Land rover style, in a hole. . Then with the window up, you lift the whole window channel and mirror assembly up about 6 inches. It's really heavy but doable. It should just sit there. Don't pulll too hard, it's still attached to the mirror wiring and also the glass and winder assemblies are all in there waiting to break.



Here it is lifted. Maybe that's four inches not six....

STEP 6

I broke the multi plug connector getting it off, and still have no sage advice as to how it's done even after staring at it on the floor. So add your comments here please but un plug the multi cord how ever you do so so it doesn't break, and then, gently but firmly slide your actuator down and out.



Step 7.

Swap your new one in, making a note of the position of the external door handle lever position, and wiggle and struggle it back up and into position. And reverse removal procedure. Don't forget to retape the plastic lining on the inside of the roor to stop dust from coming in and enjoy the delights of central locking until it breaks again.

Thanks mrapocalypse for this how to.

One important tip:

The external door handle actuator rod screws into the plastic slider as shown in the photo in Step 4. When you're installing the new mechanism make sure that this rod is screwed in the same number of turns to be the same overall length. Otherwise it may prevent the door opening at all if not set the same length. I had a mild panic attack until I realised why I my door would'nt open! Lucky I hadn't installed the interior trim so was able to rectify the problem.

Cheers
Simon