Hi all.

As per suggestions, I checked the small springs at the plastic "piston"
inside each front door actuators. The lower spring in each piston had
failed.

Image of pass. side parts: http://tinyurl.com/px6tvc2
Driver side: http://tinyurl.com/pmm66l3

All 4 springs were rusty but it appears the spring at lower end of each
"piston" rusted out and broke. This makes sense as I'm sure water tends to
pool at that point. (each rubber boot was broken at top near hook
hole). Ironically, the driver side lower spring was nearly missing but I'd
assumed the passenger side lock was causing the fault; it couldn't be moved
from the locked position. When I thumped on the outside of the driver side
door while trying to turn the key, the locks would work or become
intermittent. This likely jarred the copper bar that connects to the
stationary copper contacts (??)

I think it was David B who suggested a spring alternative and it may have
been the type I used? I sacrificed the spring out of a mini paper stapler.
Turning a slightly undersized drill BY HAND, I cleaned and sort of "milled"
(cleaned really) the holes to accept the **slightly** larger OD spring. I
applied a small amount of chain lube between springs and hole.

The old springs measured at: ~ 7.0 mm x 3.5 mm

At one actuator connector, one wire pulled off a terminal quite easily. It
wasn't hard to solder it back on.

I have yet to "button up" the job but the actuators are working so far. I
used "Goop" to seal the top of each broken rubber boot. One person
suggested a finger condom might suffice as replacement for that boot.

Safety first,

Neil.

--
Neil n

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