Body - Trunk Key Hard to Insert/Turn/Flap Broken
Bulletin No: 09-007/02Last Issued: 04/19/2002
Subject:
TRUNK KEY DIFFICULT TO INSERT OR UNABLE TO TURN KEY OR CYLINDER FLAP BROKEN
Note:
The warranty information in this bulletin has been updated.
APPLICABLE MODELS
1999-2002 Protege
DESCRIPTION
The flap inside the trunk lock cylinder assembly may become loose or damaged preventing proper locking and unlocking of the trunk. The cap and flap can be replaced separately. Use the repair procedure below to repair this concern.
REPAIR PROCEDURE
1. Verify customer concern.
^ If key cannot be inserted or cylinder cannot be rotated, key cylinder requires disassembly and removal of obstruction, proceed to STEP 2.
^ If key cylinder flap is damaged and key cylinder operates properly, proceed to STEP 3.
2. Key Cylinder Disassembly Procedure
a. Remove the cylinder from the vehicle according to Workshop Manual (section 09-14 SECURITY AND LOCKS).
b. Pry off the key cylinder cap and flap. Discard the cap and flap.
c. Remove the clip, lever, and spring washer.
d. Insert the key and remove the tumbler assembly.
NOTE:
If key cannot be inserted completely, it will be necessary to depress the exposed tumblers to remove the tumbler assembly.
e. On a clean work surface, remove each of the tumblers and place them in their specific sequence, to insure that they will be installed in their original positions.
f. Inspect for and remove all pieces of the broken flap.
g. Reinsert tumblers into their original slots.
n. Insert key into tumbler assembly.
i. With key still in tumbler, insert tumbler into cylinder.
j. Using the key, turn the tumbler inside cylinder until it seats completely into the cylinder and remove the key.
k. Install spring washer, lever and clip. Proceed to STEP 5.
NOTE:
Make sure the lever is facing the correct direction.
3. Remove the cylinder from the vehicle according to Workshop Manual (section 09-14 SECURITY AND LOCKS).
4. Pry off the key cylinder cap and remove the flap from the tumbler.
5. Install the new flap.
6. Install the new cap.
NOTE:
Make sure the claws in the cap fit into the grooves in the cylinder.
PART(S) INFORMATION
WARRANTY INFORMATION
Note:
This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.