Ford Falcon. Manual - part 433

501-14-11 

Handles, Locks, Latches and Entry Systems 

501-14-11

REMOVAL AND INSTALLATION (Continued)

Fuel Filler Door Release Switch

Removal
1.  Use a flat plastic spatula similar to a credit card to

gently remove switch assembly from crash pad.

Clipping points are on the sides of the bezel.
NOTE: Using a screw driver or similar may cause

damage to the instrument panel.

2.  Disconnect electrical connector from rear of

switch.

3.  To disassemble the switch assembly:

Gently depress locking tabs and push switch

out from bezel.

Installation
1.  Reverse removal procedure.

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501-14-12 

Handles, Locks, Latches and Entry Systems 

501-14-12

DISASSEMBLY AND ASSEMBLY

Door and Liftgate Locks

Door Lock

Disassembly
1.  Drive out the roll pin securing the lever to the

magazine. Remove the lever and spring.

Item

Description

1

Spacer

2

Wave washer

3

Tumbler

Liftgate Lock

Item

Description

1

Spacer

2

Wave washer

3

Tumbler

NOTE: The same service procedures apply to both

locks. If the key code is unknown, it can be read

through the lock drain slot as follows:

Item

Description

Position the lock with the drain slot upwards and the

operating lever to the right. Starting at the left, read

1

Shutter

the code from each tumbler by counting the number of

2.  Remove the circlip retaining the magazine.

notches on the edge of each tumbler.

3.  Withdraw the magazine and tumblers.

1 notch = 1

Assembly

2 notches = 2

1.  Open the overhaul kit and select the tumblers

3 notches = 3

required (in our example 1, 4, 3, 4, 2, 3) 4

0 notches = 4

spacers and 1 tumbler pack spring (wave

As can be seen, in our example the key code is

washer).

143423.

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501-14-13 

Handles, Locks, Latches and Entry Systems 

501-14-13

DISASSEMBLY AND ASSEMBLY (Continued)

2.  Select the correct handed magazine for the lock

7.  Holding the magazine upright between finger and

being overhauled. An R or L is stamped on the

thumb of one hand, lower the lock housing over

end of each magazine indicating the “hand” of the

the magazine, ensuring that the roller does not fall

magazine.

out and that it locates in the housing correctly.

Left hand door = L magazine
Right hand door = R magazine
NOTE: A right hand magazine is used for the

liftgate application.

8.  Keeping the magazine in place in the housing,

check that the lock operates correctly. Holding the

lock face towards you (drain slot facing down):

A Left hand lock will have 0

° freeplay to lock

(turn key to left), 45

° freeplay before

unlocking (turn key to right).

NOTE: The roller slot is the narrower of the two slots.

A Right hand lock will have 0

° freeplay to lock

NOTE: Use a pencil to insert tumblers.

(turn key to right), 45

° freeplay before

3.  Insert the tumbler into the magazine so that the

unlocking (turn key to left).

roller cutout in the tumbler is on the same side as

the roller slot in the magazine.

The first tumbler inserted should be the last

number of the key code, in our example a ‘3’.

Follow this with a spacer, again ensuring that the

roller cutout aligns with the roller slot.

9.  Up-end the assembly so that it rests on its front

face. Secure the magazine in the housing by

fitting the circlip.

4.  The remaining tumblers are inserted in the

following order: ‘2’ + spacer, ‘4’ + spacer, ‘3’ +

spacer, ‘4’ + pack spring and finally the last

tumbler ‘1’. This is our key code example 143423.

5.  Using multi-purpose grease, pack the centre of

the magazine and lubricate the magazine casing.

6.  Lubricate and then insert the roller into the slot in

the magazine.

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501-14-14 

Handles, Locks, Latches and Entry Systems 

501-14-14

DISASSEMBLY AND ASSEMBLY (Continued)

10. Refit the lever return spring onto the housing by

Disassembly

crossing the legs of the spring about the post on

1.  Remove the large circlip (A) from the end of the

the housing.

magazine.

11. Refit the lever ensuring that the spring sits

correctly about the lever and install the roll pin.

2.  Remove the small circlip (B) and withdraw the

magazine assembly from the housing.

3.  If the key code is unknown, remove the end cap

Ignition Lock

from the magazine by spreading the castellations

and working from left to right, lay out the tumblers

in a line as they are removed.

4.  Identify the tumblers (by reading the notches on

the edge of each tumbler) and write down the key

code.
NOTE: The housing is serviced as an assembly.

Individual components of the housing are not

serviced.

1 notch = 1
2 notches = 2
3 notches = 3
0 notches = 4

Assembly

Item

Description

1.  Open the overhaul kit and select the tumblers

required.

1

Spacer

NOTE: When rebuilding the lock, the first tumbler

2

Wave washer

to be inserted will be the last one removed: using

3

Shutter

our example, a ‘3’.

4

Tumbler

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