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Once the tumbler / key were out, I made a little diagram of the orientation and slowly pulled the key out, hold the wafers to keep them from flying off. Key out, wafer ends pointed horizontally, I worked from one end of the tumble to the other, pulling out wafer, marking my map with what number wafer, laying the wafers in order, and finally using a very fine pointed tweezers I pulled out all the springs.
Four of the positions have wafers that are two part (two springs) with different numbers on each sub-wafer. Not sure what that is all about, but they are a pain to keep straight and then get lined up when putting the key back in.
Be sure to keep track of the little ball bearing that is in there. It fell out before I saw where it lives, so I put it back into a small hole on the inside. That seems to be the right place for it.
Cleaned the tumbler and the cylinder really well with brake cleaner, sprayed off with compressed air. Cleaned each wafer with a rag and alcohol individually, managed to break the end off one of the springs, but re-used it anyway, didn't seem to harm the operation (yet).
Put on a very light waxy lubricant (Boeshield T9) and put it all back together, no joy. Same problem, key will turn in lock direction but not in unlock. A few of the wafers stood proud of the tumbler, so I carefully removed them and filed them done. I worked from tallest down and re-try the lock after each was corrected, until it finally works. It is still a little notchy and you have to hold your mouth just right, but it works. Put it all back together, now on to house chores....
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Respectfully,
/s/
M. Dillon
'87 124.193 (300TD) "White Whale", ~392k miles, 3.5l IP fitted
'95 124.131 (E300) "Sapphire", 380k miles
'73 Balboa 20 "Sanctification"
Charleston SC
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