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DIY: Rear Door Lock Actuator Repair - '07 335i
Published by Built My Way
08-12-2014
DIY: Rear Door Lock Actuator Repair - '07 335i

Hey all! I just saved myself a bit of money by repairing one of my door lock actuators. It didnít cost me a cent and all it took was a little of my time.

My rear passenger side door lock wouldnít unlock but the other doors seemed to be fine so I figured it had to be either an issue with wiring in the door or a problem with the actuator itself. Some quick online research convinced me that the problem was more likely to be an issue with the actuator so I decided to remove it to have a look. In the end it all boiled down to a seized actuator motor and as you read on youíll learn why it failed and how to solve the issue whether it be replacing the actuator itself or by repairing the old one.

Anyway, hereís the DIY for repairing a rear door lock actuator based on my 2007 335i e90. Please note that much of this DIY is not the usual step by step set of instructions but is more of a personal account. Nonetheless it will help guide you through the process. Letís get started.

Lock Actuator Removal:
There is really nothing out there in the way of information for rear door lock actuator removal to speak of but thanks to e90post member tracerit, his DIY for the Ďfront door lock actuator replacementí post really helped.

See http://www.e90post.com/forums/showthread.php?t=477507

All in all, everything came apart quite well. The tool kit for trim removal was a Godsend. A few nice things about doing the rear lock is that I didnít have to disconnect the battery nor unhook the glass from the window regulator. I kept the window rolled up the whole time which allowed for more than enough access to the actuator. Also, since the handle is keyless there is no need to undo the 4mm Allen bolt on the edge of the door or go near any part of the handle for that matter.

Well, you are now at a point where you have two options. You can either install a new actuator by reversing what you just did to remove the old one or continue on into the mysterious and wondrous realm of door lock actuator repair.

Actuator Housing Disassemble:
Now with the actuator in hand, my first response was that this thing is a sealed unit and cannot be opened without destroying the housing. The riveted strike plate is what momentarily fooled me but looking closely, there are five Torx20 screws; four around the plastic perimeter and one going through that same metal plating. I removed the 5 screws and noticed that the housing started to separate into what looked like two pieces.

I started pulling at the plastic tabs that hold the pieces together and began gently prying them apart. All of a sudden I could see that now there were three pieces to the unit. The third piece had the triangular shaped metal strike plate attached. The end of the triangle was easily pried off a plastic locking nub. I tried to slide the third piece straight out as it only wanted to go in one direction but it seemed to be jammed on one end so I used a bit of force (maybe too much) and then it yielded and luckily it separated without any damage or parts flying everywhere. Whew! I was a bit more cautious when separating the two other pieces. Talk about a Chinese puzzle!

Point of Failure and Actuator Repair:
I set aside the strike plate section of housing and focused my attention on separating the other two pieces. As expected, one of the halves was filled chock a block with gears, linkages and springs and the other was just a mating cover. Two toy size 12v DC motors accompanied the workings. A visual inspection showed no obvious damage to any of the exposed parts. The condition of the plastic gears looked fine. All linkages seemed to be in their place and all springs ready for action. The greased brass worm gears on the motor drive shafts showed no signs of wearing and I was able to rotate them using my thumb with little or no resistance from the motors.

Carefully, I pried one of the motors loose leaving two small +/- electrical prongs exposed in the housing base. I hooked the motor up to a 9v battery and put it through a series of stop and start tests without any problem. The other motor was a different story. It would stop alright but would only start intermittently. The motor could only be started again by rotating the worm gear with my finger.

I then separated the metal motor casing from the plastic end piece which houses the tiny brushes by straightening the two crimped metal side tabs. Inside, the brushes were in good condition but the commutator (the rotating part that the brushes touch) was black with carbon. There was also a half melted tiny nylon flat wear washer separating the rotor from the end of the plastic motor housing.

So with the motor apart, I sealed off the magnet and windings with a layer of masking tape (sticky side out) leaving only the commutator exposed. Then using very fine steel wool, I removed the carbon build up, paying special attention to the lateral grooves. The purpose of the tape is to keep the steel wool filaments separated from the magnet. After the cleaning, the motor was reassembled and tested again. It started flawlessly every time. I even cleaned up the other motor while I had everything apart. Repair complete!

Information regarding commutator surface conditions can be found here:
http://www.electrographite.co.za/cus...surface-chart/





Conclusion:
Electrical contact between the commutator and the brushes had diminished over time due to a build up of carbon. Finally the rotor could no longer overcome the resistance from the layer of residue and the motor seized. This caused an over-current situation in the door locking circuit and blew the 15A fuse.

In technical service bulletin SIB 511907 of June 2013, BMW recommends changing fuse #57 (up to 9/07 production) or fuse #73 (from 9/07 production) from a 15A to a 20A. A function test must then be performed and actuator(s) are to be replaced if locking and unlocking is sluggish or abnormally noisy. BMW blames silicon contamination or intermittent but acceptable amperage spikes. The latter may be true but Iím not sure about BMWís conclusion regarding silicon contamination. The only exposed component of the actuator is the latch.

BMWís 20A fuse and actuator replacement fix is only a short term solution to a deeper problem. In my case, the motor that drives the locking rod mechanism is failing prematurely. Black carbon residue on its commutator is an indication that it is being overworked. The motor drives a yellow groove-cam gear which controls the locking rod linkage and somehow the dynamic loading of these components is stressing the motor. (See pictures below)

Of course my conclusion is only based on one actuator but I am confident that many of the BMW and even other car brand locking system failures could be traced back to the actuator motors.

Iíve included some pictures at the end of this DIY of the open actuator to not only get a feel of what to expect but to know what order and where some of the pieces go just in case a loaded spring decides to go rogue, unleashing its power on unsuspecting neighbouring components, sending them off in all directions.



Removing the Door Handle/Pull and Handle Backing Plate (Optional):
Before reinstalling the lock actuator, I decided to take a detour and remove the entire door handle/pull workings just to see how it all fit together and it gave me a chance to clean and wax the painted surface area and to properly lubricate the sometimes Ďstickyí spring mechanism on the handle/pull backing plate. Removal of the handle and backing plate is unnecessary when doing the lock actuator fix but Iíve included a short procedure in case you decide you want to take this route.

I followed traceritís DIY and removed the 4mm Allen bolt located on the doorís edge under the black plastic circular cover. I removed the loose end block piece of the door handle, being careful not to damage the courtesy light and then pulled the end of the handle closest to the doorís edge out. The other end of the handle rotated and pulled right out. A Torx-20 screwdriver was used to loosen the exterior screw holding the backing plate to the door pull area. I slid the door handle backing plate off and fed it out through the door. Putting the handle back is somewhat tricky. Dry fit the handle/pull and the backing plate together first to understand how it goes together. Reverse the order of steps to assemble.

Here are pictures of the door handle assembly.

Backing plate (interior side)



Backing plate (exterior side)



Door handle/pull




Pretty Pictures of Inside the Actuator:
Note: These pictures only show re-placement of the components that are more likely to become dislodged during handling of the open actuator.

Order of component installation Ė left to right and top to bottom


The motors can be installed or removed at anytime during the procedure. The problem motor was the one on the right.



Yellow groove cam gear



Locking rod module with spring in place



Dry fitting the locking rod module without loading the spring to ensure that the pin on the underside lines up with the yellow groove cam gear



Installing the locking rod module by first putting the spring into place



Setting the long plastic linkage in position as shown



Loading the large spring against the plastic tab as shown



Aligning the small black slotted linkage in the channel.



Setting the second black linkage on top of the slotted one



Setting the third black linkage on the previously loaded spring and rotating it CCW over the threaded pillar, pushing it down into place. It should stay put against the pillar but just be careful not to bump it.




Putting the mating cover back on using four Torx-20 screws



Sliding the third housing piece into place making sure that it lines up properly




Attach fifth Torx20 screw as shown (lower right)



Well thatís it. Everything went back together nicely and the locking mechanism works like a charm. I plan on doing the remaining door lock actuators over time as preventive maintenance. I read somewhere that you donít have to detach the window from the regulator during front door lock actuator removal procedure. Simply unbolting the bottom of one of the window guides will provide the space needed to get the actuator out. I guess Iíll find out soon enough.

One last thing to consider: If instead, you decide that you want to replace the actuator then maybe give a thought about selling the old one. Motors donít last forever and I reckon that these in particular will become a difficult item to find in the future.

Thanks for dropping by!

Built My Way

PS: See my DIYs for the 335i Water Pump/T-Stat replacement and the Hard Brake Pedal issue.
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