Door lock deadlock release T5 2005

[Kiels3927]

Bugger! My passenger side door started misbehaving last trip out & being aware of this post, I decided not to lock it so I could get to the lock & work on it, but I forgot the Multivan autolocks when the doors are shut. Now I can't trick the passenger door into one last release.

Why is it that these darned things are quite happy locking but fail unlocking?

[Umai Naa!!]

I had the opposite on a Golf, the other day.

Anyways, give the door a thump, roughly where the latch is, while cycling between lock and unlock.

[Kiels3927]

I tried that after I posted & it worked. Door card's off & the skin is hanging on by the cable of the door lock.

Next Question: What's the size of the Torx or whatever for the door lock?

[Sunny43.5]

There about three different sizes used for the actual locking mechanism , one very important thing to remember is you have to remove the cover cap at the end of the handle . DS has a key slot but some vans have a dummy cap on the pass side you remove the grommet around the edge of the door skin there is a torx screw that needs loosening before the cap can be removed . Once you get the cap off there is a very thin wire from the handle to the lock release you must release that before removing the lock itself I used a hook ended tool to pull the metal tang out of a slot that holds the cable . When you refit the lock use the same tool to pull the wire back into the slot .

[Umai Naa!!]

The screw in the end of the door for the blanking cap for the handle is a T20 Torx. DO NOT completely remove it. Loosen it about 10 turns, and go from there. Slowly undo until the end cap can be removed. If you unscrew it far enough that it starts to bind, or feels tight, STOP. You will need to pull the handle outward slightly to remove and install the end cap.

The bolts that hold the latch in are M8 multi-spline/XZN/triple square.

[Kiels3927]

Thanks

[Kiels3927]

Just an update on the bolt tool.

Repco Indooroopilly didn't have one in stock but could supply by end of day for a $10 premium.
Super Cheap Taringa couldn't find them on their stock list though they knew of it
Trade Tools Coopers Plains were out of stock for the individual ½" drive bits, and the multi size bits but could supply a hex/torx/spline drive kit with ½ & ¼ adaptors.

The current trade name for the drive appears to be just plain spline drive, no multi.

[Sunny43.5]

When I did ours I was able to use a torx driver to remove the spline bolts at the edge of inner door area jut tapped it in and all screws came out easily , I'll never understand the need for those multi spline ones makes no sense .

[Kiels3927]

Another thing I have learned. The grommeted slot for the door handle cap is too small for all seven bit-carrying screwdrivers & drill bit holders that I own, but my salvation tool shop found a long Torx key in lieu of a purpose built torx screwdriver, the latter which are rare as rocking horse manure. Bless you again, VW, to the 7th generation.

I resisted the urge to chuck up a carbide bit & grind the panel into submission & opted for form over functionality.

[Sunny43.5]

Love your attitude , like me improvise overcome and adapt . Hmm I think I heard that expression in a Clint Eastwood Movie Heart Break Ridge . It has always been my attitude when faced with stupid ideas in cars DO YOU HEAR ME VW ? . You can unclip the door pull cable to rid yourself of the inner skin make life less stressful . Having done both sides of our old van since now sold I can now attack any future failures on our other two vans with gusto .