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Pinpoint Test G: The Manual Door Lock Cylinder Inoperative

  1. Normal Operation and Fault Conditions 

    The door lock cylinder is connected to the door latch via a lock rod and can be used to manually lock/unlock a door.

    Possible Sources 

    • Bent or binding lock rod and lever
    • Door lock cylinder
    • Door latch

  2. G1 CHECK THE LOCK AND UNLOCK OPERATION

    • Insert a key into the lock cylinder and rotate the lock cylinder to the lock and unlock positions.

    Does the door lock cylinder freely rotate without locking and unlocking the door? 

    Yes  GO to  G2
    No  GO to  G4

  3. G2 CHECK THE DOOR LOCK CYLINDER (FREE-SPIN)

    • Remove the door lock cylinder.

    • Operate the door lock cylinder with the key while holding the lever on the lock cylinder.

    Does the key in the door lock cylinder rotate freely while the lever is stationary? 

    Yes  INSTALL a new door lock cylinder.
    No  GO to  G3

  4. G3 CHECK THE DOOR LOCK CYLINDER LINKAGE CONNECTION

    • Inspect the door lock cylinder linkage.

    Is the door lock cylinder rod and lever disconnected? 

    Yes  CONNECT the door lock cylinder rod and lever.
    No  INSTALL a new door latch.

  5. G4 CHECK THE LOCK CYLINDER OPERATION AFTER LUBRICATION

    • Spray a lock lubricant (such as Motorcraft® XL-1) into the lock cylinder opening for a couple seconds.

    • Operate the door lock cylinder with the key.

    Does the door lock and unlock using the door lock cylinder? 

    Yes  The concern was caused by an insufficiently lubricated lock cylinder. SPRAY a multi-purpose grease (such as Motorcraft® XL-5) into the lock cylinder for a couple seconds to provide long term lubrication.
    No  GO to  G5

  6. G5 CHECK THE DOOR LOCK CYLINDER FOR BINDING

    • Remove the door lock cylinder.

    • Operate the door lock cylinder with the key.

    Does the door lock cylinder rotate freely? 

    Yes  GO to  G6
    No  INSTALL a new door lock cylinder.

  7. G6 CHECK THE DOOR LOCK CYLINDER LINKAGE

    • Operate the door lock cylinder while observing the linkage.

    Is the door lock cylinder rod and lever binding, damaged or disconnected? 

    Yes  REPAIR as necessary.
    No  INSTALL a new door latch.
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