Modification Procedure, Door Latches and/or Microswitches
MODIFICATION PROCEDURE (405 Sedans and Sportswagons):
DOOR LATCHES AND/OR MICROSWITCHES
Disassembly:
- Remove the three armrest attaching screws (1).
- Unclip door lock handle trim ring (2) by pulling it straight out.
- Remove plastic trim on sideview mirror gusset (3).
- On "DL" vehicles, pull off window crank handle (4).
- Remove inside lock button (5) as follows:
- Make sure lock button is in the unlocked (up) position.
- Using a small flat-blade screwdriver (A), push in and down on tab (B) in upper slot (C) to disengage internal jaw from the lock rod, and remove lock button.
- Carefully pry the door panel loose from the inner door by disengaging the clips along its edges with your fingertips or suitable tool (such as Snap On #A161A Trim Pad Remover or equivalent).
- Lift the door panel off of the window channel to remove it.
- Unplug front speaker connections, if equipped.
- Remove inside door handle by pushing it forward to release locking tabs.
- Carefully peel back self-adhesive insulating sheet to expose access hole in door, as shown.
- Unclip and remove door lock rod from latch assembly (Sedan only).
- Remove door handle pull rod from latch assembly (Sedan only).
- Remove hold-down clip from lock tumbler. This can be more easily accomplished by removing the two rubber plugs from the end of the door, with a screwdriver or similar tool. Do not remove the lock tumbler at this time.
- Locate the wiring harness, for the door lock motor and microswitch, on the inside of the door and remove it from the clip closest to the latch assembly (Sedan only).
- Remove the three torx head bolts in the end of the door to secure the latch.
405 Sportswagon
- Replace the microswitch at this time. Remove the two-pin electrical connector and slide the old switch off of the door latch. When installing the new switch, make sure it is fully seated in the latch.
- Reinstall door latch and door panel trim (see Reassembly).
- See Checking Procedure.
405 "S" Sedan
- Remove the door lock tumbler.
- Lift door latch assembly through access hole in door, and remove central lock motor by rotating it about 1/8 of a turn away from the locking lever on the latch.
Prepare the new latch for installation as follows:
- Make sure the plastic grommets (1) and clip (2) are installed in door latch as indicated.
- Transfer door lock rod for tumbler (4) to new door latch.
- Ensure that microswitch is fully seated on door latch.
- Install central door lock motor (5) with the pin on the locking lever in the upper hole of the lock motor plunger.
- Reinstall door latch and door panel trim. See Reassembly.
- See Checking Procedure.
Reassembly (405 Sedans and Sportswagons):
- Reinstall all components in reverse order of disassembly.
- When installing the door latch, make sure the latch release arm is properly positioned on top of the exterior door handle activator.
- Install lock tumbler assembly through door and onto lock rod before mounting the latch assembly to the door.
- When installing the door panel trim, make sure of the following:
1. Speaker wire connector is properly clipped to the inside of the door.
2. The lip along the top edge of the door panel properly engages the weatherstrip in the window channel.
3. All door panel retaining clips are fully seated in the door, especially the one behind the speaker grill. Replace any clips that will not hold (P/N 6992.51).
To install door lock button:
- Lock rod in unlocked (up) position.
- Push up internal jaw to disengage tab B from lower slot D, but not all the way to slot C, as shown on page 2.
- Install button over lock rod, being careful to engage tab F into slides in door panel.
- Push down on lock button until tab B appears in slot C.