Ok, a year after being asked to do this, here goes. If I can do it anyone can!

Issues could be

a] door lock screwdrivered during attempted break-in

b] Key flap broken/dislodged

c] Barrel refurb.

Tools required:

Allen key, 3mm
Pliers long nose
Screwdriver, long flat blade
Screwdriver, small phillips
Bradawl, very small or tiny [1mm] screwdriver
Hammer, small
Grease, a little

First remove the door handle thus:

As in first pic. unscrew bolt in door edge with allen key [I'm sure it was a phillips screwdriver in my 16vt]

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030008.jpg

* * *
Next with the window wound down pull back the rubber seal level with the handle to reveal three small plastic pop studs and ease them out gently, extracting them with pliers.

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030009.jpg

* * *
Pull away the seal which gives access to the inner channel for the window and ease it out from the top

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030010.jpg

* * *
With this out of the way undo the two remaining bolts which secure the door handle. NB be careful not to drop them inside the door! If anxious put a cupped piece of card under them. The handle will nearly come free.

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030012.jpg

* * *
Use the long flatblade to prise off the two plastic ball and socket joints.

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030013.jpg

* * *

Now you're back inside with the business. Eke out the horseshoe spring which sits right next to the main body of the door handle.

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030015.jpg


* * *

Undo the two phillips bolts which secure the barrel housing and it will come out.

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030016.jpg


* * *

Insert the key into the barrel and push the opposite end of it to release the barrel from the housing.

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030017.jpg


* * *

If the nylon collar is still intact remove it carefully

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030018.jp

* * *

With the tiny screwdriver/bradawl prise open at least three of the pinch points - you will need the hammer for this but don't go con belto

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030001.jpg

* * *

Here on the left is a pic of my screwdrivered barrel where the top half was snapped off. Note the tiny spring which operates each leaf, also the end of the brass rod at the bottom which holds all the leaves in place and pulls out if you need to refurbish any of them. On the right is an empty shell, complete.

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030002.jpg

* * *

With the bar partly extracted showing the rear two leaves freed off.

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030010-1.jpg

* * *

This is how the keyflap spring should be situated with the lower bend on the left resting against the barrel and the upper end ready to press down with the keyflap. Note the key is threaded through the disc.....
(Edit: having done this again recently the spring operates better with the leg nearest the middle of the barrel uppermost)
click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030008-1.jpg

* * *

Now this is the cunning part that should need three hands, but as said above, put the key through the disc first then insert the key halfway into the barrel. You can then introduce the flap into its sockets [the right way up, ie flange pointing downwards] having already compressed the upper end of the spring beneath it. The flap itself will be disappearing inside the barrel.
With the key and you holding this in place slide the disc back onto the housing and re-pinch it. This is where you may want to apply some protective grease on the barrel.

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030009-1.jpg


* * *

As the time-honoured saying goes when putting everything back:

R is the R of R!

click to enlarge
http://i591.photobucket.com/albums/ss354/Edinburgh_photo/Coupe%20lock%20refurb/PA030029.jpg

* * *

Flap now operational again and ready for the winter.
NB if the flap doesn't close fully after the above check that the disc is perfectly flat.

Last edited by Edinburgh; 13/12/2018 21:23.

Thanks again, Photobucket.
BumbleBee under restoration...