Ford Falcon. Manual — part 433
501-14-11
Handles, Locks, Latches and Entry Systems
501-14-11
REMOVAL AND INSTALLATION (Continued)
Fuel Filler Door Release Switch
Removal
1. Use a flat plastic spatula similar to a credit card to
gently remove switch assembly from crash pad.
Clipping points are on the sides of the bezel.
NOTE: Using a screw driver or similar may cause
damage to the instrument panel.
2. Disconnect electrical connector from rear of
switch.
3. To disassemble the switch assembly:
Gently depress locking tabs and push switch
out from bezel.
Installation
1. Reverse removal procedure.
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501-14-12
Handles, Locks, Latches and Entry Systems
501-14-12
DISASSEMBLY AND ASSEMBLY
Door and Liftgate Locks
Door Lock
Disassembly
1. Drive out the roll pin securing the lever to the
magazine. Remove the lever and spring.
Item
Description
1
Spacer
2
Wave washer
3
Tumbler
Liftgate Lock
Item
Description
1
Spacer
2
Wave washer
3
Tumbler
NOTE: The same service procedures apply to both
locks. If the key code is unknown, it can be read
through the lock drain slot as follows:
Item
Description
Position the lock with the drain slot upwards and the
operating lever to the right. Starting at the left, read
1
Shutter
the code from each tumbler by counting the number of
2. Remove the circlip retaining the magazine.
notches on the edge of each tumbler.
3. Withdraw the magazine and tumblers.
1 notch = 1
Assembly
2 notches = 2
1. Open the overhaul kit and select the tumblers
3 notches = 3
required (in our example 1, 4, 3, 4, 2, 3) 4
0 notches = 4
spacers and 1 tumbler pack spring (wave
As can be seen, in our example the key code is
washer).
143423.
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501-14-13
Handles, Locks, Latches and Entry Systems
501-14-13
DISASSEMBLY AND ASSEMBLY (Continued)
2. Select the correct handed magazine for the lock
7. Holding the magazine upright between finger and
being overhauled. An R or L is stamped on the
thumb of one hand, lower the lock housing over
end of each magazine indicating the “hand” of the
the magazine, ensuring that the roller does not fall
magazine.
out and that it locates in the housing correctly.
Left hand door = L magazine
Right hand door = R magazine
NOTE: A right hand magazine is used for the
liftgate application.
8. Keeping the magazine in place in the housing,
check that the lock operates correctly. Holding the
lock face towards you (drain slot facing down):
A Left hand lock will have 0
° freeplay to lock
(turn key to left), 45
° freeplay before
unlocking (turn key to right).
NOTE: The roller slot is the narrower of the two slots.
A Right hand lock will have 0
° freeplay to lock
NOTE: Use a pencil to insert tumblers.
(turn key to right), 45
° freeplay before
3. Insert the tumbler into the magazine so that the
unlocking (turn key to left).
roller cutout in the tumbler is on the same side as
the roller slot in the magazine.
The first tumbler inserted should be the last
number of the key code, in our example a ‘3’.
Follow this with a spacer, again ensuring that the
roller cutout aligns with the roller slot.
9. Up-end the assembly so that it rests on its front
face. Secure the magazine in the housing by
fitting the circlip.
4. The remaining tumblers are inserted in the
following order: ‘2’ + spacer, ‘4’ + spacer, ‘3’ +
spacer, ‘4’ + pack spring and finally the last
tumbler ‘1’. This is our key code example 143423.
5. Using multi-purpose grease, pack the centre of
the magazine and lubricate the magazine casing.
6. Lubricate and then insert the roller into the slot in
the magazine.
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501-14-14
Handles, Locks, Latches and Entry Systems
501-14-14
DISASSEMBLY AND ASSEMBLY (Continued)
10. Refit the lever return spring onto the housing by
Disassembly
crossing the legs of the spring about the post on
1. Remove the large circlip (A) from the end of the
the housing.
magazine.
11. Refit the lever ensuring that the spring sits
correctly about the lever and install the roll pin.
2. Remove the small circlip (B) and withdraw the
magazine assembly from the housing.
3. If the key code is unknown, remove the end cap
Ignition Lock
from the magazine by spreading the castellations
and working from left to right, lay out the tumblers
in a line as they are removed.
4. Identify the tumblers (by reading the notches on
the edge of each tumbler) and write down the key
code.
NOTE: The housing is serviced as an assembly.
Individual components of the housing are not
serviced.
1 notch = 1
2 notches = 2
3 notches = 3
0 notches = 4
Assembly
Item
Description
1. Open the overhaul kit and select the tumblers
required.
1
Spacer
NOTE: When rebuilding the lock, the first tumbler
2
Wave washer
to be inserted will be the last one removed: using
3
Shutter
our example, a ‘3’.
4
Tumbler
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