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1991 FC Vert Passenger Door Lock Actuator / Solenoid Repair (How-To)
Recently, my passenger door lock lost the “follow me” ability to lock when the driver side door lock switch was placed in the “Lock” position. I could not hear the solenoid click when commanded by the driver side switch. The passenger door switch would follow the driver side switch when placed to the “Unlock” position and hence the solenoid would actuate the linkage.
Today, I decided to investigate the solenoid and see if I could repair it. Please consider this a “how to” on the Passenger Door Lock Solenoid (Actuator) for the S5. It may also apply to the S4 or anyone who retrofitted this solenoid. I was surprised that such a how-to was not previously done! Without further ado...here’s my experience:
1. Remove door card to reveal plastic barrier.
CAUTION: The triangle cover to the mirror is fragile, be careful when removing it. Don’t forget to disconnect the door light and power window connectors.
Door card removed to show plastic barrier and other door guts.
2. Peel back plastic barrier from tar strip at the lower right section of the door. Be careful of the black tar; it gets everywhere!
NOTE: Use WD-40 to remove tar from skin, tools, etc…
3. Locate and remove the bottom two (2) bolts with a 10mm socket. One bolt is below the barrier and the second bolt is behind the barrier.
Solenoid bolts (10mm) are here.
4. Disconnect the lock linkage from the solenoid. Pinch the end of the linkage with a pair of needle nose pliers then pull linkage away from solenoid.
5. Follow the wire from the solenoid and disconnect it from the harness.
6. Use a pair of needle nose pliers to pinch the plastic clip then pull the clip away from the door.
7. Remove the solenoid from the door and try not to get any of that tar on you.
8. The solenoid will look something like this.
Solenoid (front)
Solenoid (back)
9. Use a hobby knife to cut along the cloth tape. I followed along the seam because there was a respectable gap to peel the tape back.
Hobby knife cuts along cloth tape (1).
Hobby knife cuts along cloth tape (2).
10. Use a screw driver to remove the six (6) screws to the solenoid cover.
Six screws hold cover in place.
11. The cover can now be easily removed; I rotated this cover over with most of the cloth tape intact.
Solenoid cover removed.
12. The linkage transfers rotational motion from the gear into the up-down motion required to lock and unlock the door. The gear below the linkage is held in place by the top cover, it will pop out. It is actually a multi-part “clutch” and worm gear.
13. Lift the linkage bar out of the way, this cannot be removed so please do not damage it.
14. Remove the gear and the spring in between the gear disc and then remove the lower gear.
CAUTION: Damage to the armatures under the lower gear may occur if gear is mishandled.
15. Once removed, the lower portion of the solenoid is clearly visible.
Solenoid housing with gears removed.
16. Clean the underside of the gear disc with isopropyl alcohol and a cotton swab, this photo shows how dirty it was before it was cleaned.
Bottom of gear disc (dirty).
17. Repeat the cleaning process for the inside of the lower gear. Note, I left the spring inside the hub.
Inside the lower gear with spring.
18. Inside the solenoid housing, clean the inner and outer track with isopropyl alcohol and a cotton swab. Note how dirty the tracks were in the photos.
Examine circular tracks for cleanliness.
Dirty tracks.
19. This photo shows the cleaned gear disc and lower gear with spring inside the hub.
Gear internals cleaned.
20. Turn the lower gear over and inspect the armatures.
Bottom view of lower gear.
21. Use a fine abrasive to LIGHTLY remove any build up on the armatures. I used 1,000 grit sandpaper.
22. Use the same fine abrasive to LIGHTLY remove any build up on the circular tracks inside the solenoid.
23. Clean both tracks and armatures again with isopropyl alcohol and a cotton swab.
24. Apply a thin layer of dielectric grease to the armatures and the circular tracks with a tooth pick/cotton swab. Refer to the photos.
Dielectric Grease used for project.
Apply dielectric grease to armature tips.
Apply dielectric grease to outer circular track.
Apply dielectric grease to inner circular track.
25. Inspect the armatures for equal height. My method was not precise, just “eyeballed” it. As necessary, bend up the lower armature to ensure proper contact with the circular rings in the solenoid housing.
CAUTION: Do not use excessive force or put harsh bends on the armatures because they could break. Be sure to support the thin metal when reshaping the armatures.
Inspection of armatures.
26. Place the lower gear back into the solenoid housing. It is necessary to angle the linkage out of the way in order to fit the lower gear into place. It will be in the way but it is possible to fit the gear over the shaft without causing damage to the armature or shaft.
CAUTION: Use care when installing the lower gear. Do not bend the shaft or damage the armatures when installing the lower gear.
27. Then place the gear disc on top of the lower gear and ensure it will mesh with the linkage. This step is not shown in the photo.
Lower gear and spring installed.
28. Close the cover then install the six (6) screws following a directional pattern. (photo 22 & 23)
Solenoid cover installed.
Tighten 6 screws in directional order.
29. Connect the solenoid’s electrical connector on the door and test its operation. The solenoid should now follow the driver door switch when it is moved to the “Lock” and “Unlock” positions.
30. After test is completed, installation of the solenoid and door parts is in reverse order.
Thank you for the compliment! I approached this repair from the perspective of a how-to guide first then fixing the problem 2nd because no such write-up existed. I was surprised to learn that no one previously had a detailed write-up. At least it wasn't obvious in the search criteria. I wish this repair guide helps others as much as it helped me.
For those members who use this how-to, please give feedback when appropriate.
Thank you for the compliment! I approached this repair from the perspective of a how-to guide first then fixing the problem 2nd because no such write-up existed. I was surprised to learn that no one previously had a detailed write-up. At least it wasn't obvious in the search criteria. I wish this repair guide helps others as much as it helped me.
For those members who use this how-to, please give feedback when appropriate.
Cheers,
George
George,
Well you've done an excellent job and should consider doing a few more of these while you're working on your car. The world could use a place where more of these writeups are available. I need to consider doing a few of these as well.
Best of luck,
Austin
Originally Posted by No_love_for_pistons
Great writeup! This should be stickied! I'd recommend adding a link to it in your signature.
Sticky'ed or archived for sure! Adding it as a link in a signature is a good idea as well.
Thank you for the compliment! Adding this fix to my sig would be ok but I have several other how-to's on the FC & FD. The sig line would be too big! Refer to this thread for a link to my contributions to the forum: DIY / How-To / Troubleshooting Thread Links by Gen2n3: https://www.rx7club.com/2nd-generati.../#post12229589
These threads were made to benefit the forum, I receive no other benefit by adding it to my sig line. Thank you for making the suggestion though! Perhaps these links would stir additional thought now?
Cheers,
George
Last edited by Gen2n3; 11-04-17 at 11:19 PM.
Reason: Created new link to other How-To's
10-20-17, 04:57 PM
1991 FC Vert Passenger Door Lock Actuator / Solenoid Repair (How-To)
