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jimsss J I have a problem with my B5.5 2004 Passat that is turning into a nightmare. I had an intermittent fault on my driver side rear door lock, where often it would be locked shut and the central locking would not unlock the door. I eventually got the door open and stripped down the door, and found that the door mechanism unit was faulty. Rather than attempt a repair I purchased a used one (advertised as tested). Today I have fitted the new mechanism, plugged in the loom and all was good - I could hear the motor moving fine. Put the door back together - all ok. Central locking still working. Shut the door, and when unlocking, the door seems to unlock - but the door cannot be opened. It is almost like the door lock is jammed/broken/faulty. I managed to get the door card off the door from the inside, and gain access to the door lock/mechanism - but cannot open the door! If I pull latch, move the mechanism, nothing is working to open the lock. Any pointers appreciated. It looks like this lock is faulty and the next step is to smash the mechanism apart some how to get a bit further. #1 · Nov 14, 2010 I have a problem with my B5.5 2004 Passat that is turning into a nightmare. I had an intermittent fault on my driver side rear door lock, where often it would be locked shut and the central locking would not unlock the door. I eventually got the door open and stripped down the door, and found that the door mechanism unit was faulty. Rather than attempt a repair I purchased a used one (advertised as tested). Today I have fitted the new mechanism, plugged in the loom and all was good - I could hear the motor moving fine. Put the door back together - all ok. Central locking still working. Shut the door, and when unlocking, the door seems to unlock - but the door cannot be opened. It is almost like the door lock is jammed/broken/faulty. I managed to get the door card off the door from the inside, and gain access to the door lock/mechanism - but cannot open the door! If I pull latch, move the mechanism, nothing is working to open the lock. Any pointers appreciated. It looks like this lock is faulty and the next step is to smash the mechanism apart some how to get a bit further. Sort by Oldest first Oldest first Newest first Most reactions #2 · Nov 14, 2010 I'm guessing you have the outside door handle cable too tight. Let me find the thread. #3 · Nov 14, 2010 http://www.passatworld.com/forums/showthread.php?t=319323&highlight=door+cable+tight #4 · Nov 14, 2010 I saw that tread, however with the door locked shut, can I get that small cable off the door latch? I guess the only way is to get a screw driver in there and try and piddle it off? #6 · Nov 14, 2010

jimsss said: I saw that tread, however with the door locked shut, can I get that small cable off the door latch? Click to expand...

No. The slug that slides into the door (where the lock cylinder would be if this were one of the front doors) holds the end of that cable in the groove. When that cable is adjusted too tight, it keeps the latching mechanism from actioning completely through a cycle. Try this... From the outside with the door unlocked, grab the handle and push it in towards the door. Push hard, but not hard enough to break anything. If the cable adjustment is just slightly too tight, this will slack it enough to allow the mechanism to finish cycling and the door can then be opened. Once open, you can access the parts and do your adjustment. Show more replies 0 Reply #5 · Nov 14, 2010 Pull the outside door handle out and use a small screwdriver to pop the cable off. Reattach it a notch looser. (you can see the teeth in there) #8 · Nov 20, 2010 Turns out the cable on the replacement mechanism was one full inch smaller than the old one. That was my trouble. That little problem is solved and now another: when putting the handle plug back in, the brass clip that must sit on the casing that winds tight as you wind in the screw on the outside of the door behind the rubber seal fell into the bottom of the door. It was too loose. So I had to take every out again to get the brass clip back in place. However, I can't locate it properly around the housing. When I wind the screw in on the outside of the door, the clip just gets looser. It is also very loose when the screw is wound out (to enable the handle spacer to go back in). V frustrating, what should have been a small job to replace a dodgy door mechanism has taken hours. Any help is much appreciated with getting this brass clip back into the correct position. #9 · Nov 20, 2010 I hate to maybe throw a wrench in all this, but by accident I found on my Vag-com that my right rear door lock mechanism was throwing an intermittent code (that did not throw a CEL). I replaced my driver side door window switch component that fixed the intermittent problem I was experiencing with my right rear door lock and right rear window operation. Common sense told me that it should have been an issue in my right rear door lock assembly. But it wasn't. And replacing the master window lock switch fixed it 100%. #10 · Nov 20, 2010 Another reason to always have a Vag-com at the ready.:thumbup: 0 Reply #11 · Nov 21, 2010 Got the clip on, nightmare. I have learnt a lesson, do not wind the holding screw out any more than necessary! Easy when you know how but v awkward. #12 · Dec 23, 2013 (Edited) 2004 5.5 Drivers side rear passenger door locked shut Having had an intermittent fault on the drivers side passenger door for some time, which only opened in a locked state; by pulling the interior door release, whilst pressing the remote release, I decided it was time to replace the lock with a second hand OEM unit. This was successfully completed and operated fine on the latch, except that now once closed and locked the door would not unlock and open at all. PANIC. On reading many forums I eventually came across this one, and noted the comment from Steve in Chicago that the wired slug in the external handle was fitted too high up the ratchet grooves in the handle causing the lever on the lock mechanism to be active rather than in its "at rest" position; so causing the electrical circuit when activated by the remote to fail. The solution if you are lucky, as I was, is, with the car remote unlock button pressed, to thump the rear end of the actual handle firmly with the back of the fist. So forcing the wired slug back slightly towards the lock face, causing the electrical circuit to engage and operate; hey presto the door is unlocked. Once unlocked, remove the rear end of the stub handle, (as described elsewhere to change the lock), release the slug by levering /popping it out with a small screwdriver having noted its position. Replace the slug into the grooves without stretching the wire, (now showing several more grooves). Test the integrity of the opening and locking function by holding your finger on the slug to prevent it popping out and by closing and opening the door, without replacing the end of the stub handle and by operating the remote. (if it doesn't unlock, then pop the slug and refit showing one more groove). When satisfied after repeating the test several times replace the end of the stub handle and tighten the locking star socket in the end of the door. Nb. When starting this procedure if you you do not hear the lock motor trying to operate the lock when operating the remote, then the lock is probably defective, and the above procedure is unlikely to work from the offset. MANY many thanks to all previous contributors who have enabled me to overcome this problem. I hope the above is of assistance to others. Insert Quotes Post Reply

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