Assembling and Coding the Free-Wheeling Front Side Door Lock Cylinder

The free-wheeling front side door lock cylinder uses eight of the ten key cut positions, 3-10. The tumbler positions are staggered from side to side with four on one side. The right and left side door lock are identical except for the lever (3) and rod retainer (13). The right lever is color-coded, yellow and stamped with the letter R001 and the left lever is color-coded olive drab and stamped with the letter L001. The right rod retainer is color coded yellow and the left rod retainer is color coded green. This determine on which side of the vehicle the lock cylinder will be installed.

1. Hold the uncoded cylinder (10) positioned so the sidebar is facing to the left and the four spring wells is facing upward.
   Fig 1: Inserting Tumbler Spring Into Four Tumbler Spring Wells

   Courtesy of GENERAL MOTORS CORP.
   IMPORTANT: The free-wheeling front side door lock cylinder tumblers (11) are not self retaining and must be held in place if the key is not fully inserted into the lock cylinder or until the cylinder (10) is assembled into the case (12).
2. Insert one tumbler spring (6) into the four tumbler spring wells.
Fig 2: Identifying Key Cutting Depths
Courtesy of GENERAL MOTORS CORP.
3. The first tumbler to be loaded will be key cut position, number 4. Determine the cut depth at this position and install the corresponding tumbler (1) into the tumbler slot nearest the front of the lock cylinder assembly, the end where the key is inserted.
Fig 3: Installing Three Remaining Tumblers Into Tumbler Slots
Courtesy of GENERAL MOTORS CORP.
4. Install the three remaining tumblers (11) into the tumbler slots located at key cut positions 6, 8 and 10.
5. Inspect for correct loading of the tumblers (11) by inserting the matching key into the cylinder (10). All tumblers (11) should be flush with the outside diameter of the cylinder (10).
6. Turn the cylinder (10) so that the side with the three tumbler spring wells is facing upward and then remove the matching key. The tumbler (11) are not self-retaining and must be held in place.
7. Insert the tumbler springs (6) into the four tumbler spring wells.
Fig 4: Identifying Key Cutting Depths
Courtesy of GENERAL MOTORS CORP.
8. The first tumbler to be loaded will be key cut position number 3. Determine the cut depth and install the tumbler (1) into the tumbler slot nearest to the front of the cylinder.
Fig 5: Installing Three Remaining Tumblers
Courtesy of GENERAL MOTORS CORP.
9. Install the three remaining tumblers (11) into the tumbler slots located at key cut positions 5, 7 and 9.
10. Inspect for correct loading of the tumblers (11) by inserting the matching key into cylinder (10). All tumblers (11) should be flush with the outside diameter of the cylinder (10).
11. Lightly lubricate the tumbler (11) surfaces using the provided lubrication.
12. Install the sleeve (5) into the case (12). Ensure the sleeve (5) is oriented and inserted so that the back of the sleeve is flush with the back of the case (4).
13. With the matching key fully inserted into the coded cylinder, install the coded cylinder into the case assembly (12).
14. Remove the matching key being careful to keep the coded cylinder (10) fully inserted into the case assembly (12).
15. Insert one shutter spring (9) each into the two shutter spring holes located on the front face of the cylinder (10).
16. Install the shutter assembly (8) into the recessed area in the front face of the cylinder (10). Ensure that the ends of the pin on the shutter assembly (8) are positioned in the pin cavities located on the front face of the cylinder (10).
17. Install the lock cylinder cap (7) by aligning the rectangular hole in the cap with the drain hole located on the bottom of the case (12). Snap the cap (7) into place with light hand pressure. Insure the cap is securely retained on the case and that the shutter springs (9) is push in the shutter assembly (8) up against the inside surface of the cap.
18. Install clutch (4) onto rear end of cylinder (10). Ensure the clutch (4) mates with the engagement tab on the cylinder (10).
19. Set return spring (3) onto rear of cylinder assembly with the first leg engaged with the clutch (4).
20. Hook second leg of return spring (3) onto opposite clutch (4) finger by compressing and rotating spring leg counter-clockwise. The return spring (3) will need to be help in place until the lever (2) and retaining ring (13) are properly installed.
21. Install the appropriate lever (2) right or left onto the end of the cylinder (10) so that the lever (2) engages the fingers of the clutch (4). The ID stamp of the lever (2) should face toward the cap (7) at the front of the cylinder assembly.
22. Install the retaining ring (13 in the groove at the end of the cylinder to secure the lever (2) to the cylinder.
23. Snap the appropriate rod retainer (1) right or left into the hole in the lever (2).