Door lock removal, installation.

[dubadxx]

I ordered a set of new keys from the dealer based on VIN #. All I had was the valet key when I purchased the car, "82 240D. $41(for the keys, not the car!), not bad, but as luck would have it, the new keys don't fit the drivers door, as did not the valet key. So obviously the lock cylinder is broken, or has been replaced, and who knows who the previous owner was (got the car at a used car dealer, so no records of course, yes I know!)
The dealer quoted me $210 for a new lock and handle, not incl. labor. My '83 donor car has functionong locks, so of course I'd like to use them. I've read horror stories about this job for DIY. Anybody do this job, and how grueling is it?
Oh. and I already broke one of the new keys in the lock, without using tooo much force!

[Biodiesel300TD]

Did you break the key or just tear the plastic head off? If you tore the head off see here for a DIY for making a wood key head - http://www.peachparts.com/shopforum/diesel-discussion/312435-diy-wood-key-head.html

You might try cleaning the tumbler out. They tend to get pocket lint stuffed in there, which can jam them up. My 82 wagon had a door lock that wouldn't work, I to the assembly to a lock smith and they cleaned it out and it worked like new. I haven't take the tumbler out of the door lock, but it shouldn't be too hard once you have the lock mechanism out of the door.

[BodhiBenz1987]

I pulled the tumbler out of my 240D a few years back and cleaned each little leaf one by one. It wasn't that bad a job as I remember, other than you have to be VERY careful not to mix up the leaves, or lose any of the little springs. Years of elements and whatever grease the PO squirted in there can really tie up the tumbler. Mine doesn't actually work that great now (a little resistant), but it is a huge improvement over where it was before (couldn't get the key in). This is what it looked like when it came out:

Cleaned up:

If you do try to remove the tumbler, keep the key in it as you remove it (or as far in as the key will go) because otherwise all the leaves will fall out and get out of order ... mine didn't because they were so agglomerated in there ..

[jpizano23]

I recently had to remove the outside handle, the door latch, and the interior mechanism. Ever since I bought my 300TD the door locks never worked, I had a bad leak in the locking system. I removed the door panel to look for the problem and found the someone had removed the master lock switch and attempted to plugg up the lines with screws and RTV, what a mess! The vacuum hoses were held together by masking tape.

To top it all off, the latch would work opening and closing the door but wouldnt' allow me to lock it either from the outside with the key or pushing down on the knob. Taking apart the door lock components didn't take too long and it sounds like you only need to remove the outside handle to clean the tumbler.

There are a few bolts on the side of the door that you need to get the handle out, once you remove those bolts, wiggle the handle a little to get it to release from the door latch and it's out. Here's a nice link I found to clean your tumbler:
PeachPartsWiki: Door Lock Repair