Replacing lock-mech on BMW system case

[RandyRandy]

Replacing the lock-mechanism on BWM system case...

Anybody done that? Not just the lock cylinder, but the whole stinking thing including the locking flange. I bought the replacement part... now for removal of the existing one. How'ya get the rivets inside the case out? Just drill into them or what? Any tricks?

Cheers,

RandyRandy
(First one's an adjective)

[denverchuck]

Yeah RR you’ve got it about right, just took a quick run to the garage to take a look - it’s been about a year since I did it myself.

From what I can remember, prior to drilling out the rivets, you need to push the pin holding the rubber grommet/gasket/boot on the latches to one side or the other. You need to remove that rubber piece or you’ll never be able to pull the handle out. Pushing those pins out is a minor beeyach.

There were fairly detailed instructions out there somewhere…….but I have no idea where, good luck.


dc

[Optimus Prime]

I didn't need to drill anything when I did it, unless I'm thinking of something else. Here's how I did it:

1. Unlock case and raise handles. Look for small hole in the handle recess on the lock side (right by where the "orange" lock thingy comes out)
2. Straighten a paper clip and stick into the small hole, this will push a release on the locking cylinder
3. Wiggle both the paper clip and key (which is in the locking cylinder) while trying to pull the locking cylinder out. I believe a twist may also be in order.
4. Locking cylinder pops out.
5. Reverse for inserting.

EDIT: Nevermind, I missed this part

Not just the lock cylinder, but the whole stinking thing including the locking flange.

[DJ Down Under]

Ooooh....Oooh........I know the answer to this one....I've done it.

The case has three main parts...the lid half...the inner half....and the lock handle mechanism half........yes three halves....does that add up??..:)

I swapped the inner half for a full size one after removing my can so I had to drill out and swap over the lock/handle/mechanism part.

Before I go on...am I on the right track here with answering your question...???

DJ

[R4R&R]

Yes DJ, you're on the right track (I need to do this too but haven't looked into it too much). Go on, with pictures if you have them!

[RandyRandy]

Hi DJ,
How'd ya do it? Any gotcha's or tricks?
Thanks in Advance

[DJ Down Under]

OK guys here's what I did...and pics to do the talking for me...:D

DJ

Here's my full size left case.



This is the lock/handle mechanism that needs to be taken out of the original case..as you can see there's no rivets,screws or bolts on the outside.



Inside the case there's seven rivets that need the heads drilled..be careful not to drill too deep.



You also need to use a center punch or nail to punch out these pins..one on each side of the case..and slip off the plastic thing with the pad on one side.



The handle/mechanism can be removed now....next is to drill out the rivets that hold the lid and hinge to the the old inner.

I replaced the rivets with little bolts...mostly because I couldn't find any rivets an inch long...gees they're long...the bolts will let me swap to city lids easier.

Inside view....rivits to the lid one side...bolts to new full size inner the other side.



Outside view.



My new full size inner came with hinges...here's the old hinge showing the length of those rivits...and the little bolts that I used.



You can now re rivet the handle/mechanism to the new full size inner...these are the rivets that I used...they're not as long as the lid ones...almost..:)



There ya go...all done...easy peasy...I hope this helps anyone either swapping the inner or swapping the handle/mechanism.

Oh yeah...don't forget to put those little plastic things with the pad on one side back on..and tap the little pin back through.

DJ

[R4R&R]

Awesome! Thanks DJ! I'm heading out to the garage now to get started.

I like your exhaust tip but can't find any in my area. Feel like picking one and and mailing it to me? I can paypal you the money.

[DJ Down Under]

No probs...I check out what's available and get back to you...the only problem in a $10 tip might cost $20 to post...anyway I'll suss it out.

How is it going...your case....any probs???

DJ

[R4R&R]

My case/lock swap is done! Thanks for the pictures - they helped a lot. I should've taken pics while I did it but I don't have the patience to stop and take them. The only difficulty I had was removing the old lock tumbler (:omg: :confused: ) but finally mamanged to get it out. .....and find the correct size rivets. I'm not sure if you remember, but I had my right case come off while on my ride home a few months ago. Yeah, I'm finally getting around to the repair now.

Thanks again!

[RandyRandy]

DJ,

Thanks for the all the pictures. I got mine done today. See where the orange lock-flange thingy isn't? That's because Farmer Brown sawed through it to open up my case which he found on the side of the highway. Good man he was, he found my telephone number inside and called me up and returned the case to me. (Next time, I'll be putting my telephone number on the outside of the case).

Anyway, the only part that I had to replace was that lock flange thingy... cheaper that a whole new case.

Optimus, thanks for the help on the lock cylnder extraction!

Cheers,
Randy Randy