[RCinSTP]

I followed the standard procedures for replacing the door lock actuator mechanism in the drivers door (see steps below). I did something wrong, because when I replace the lock cylinder it won't lock in place and stay. I turn the set screw all the way in but I can still pull the cylinder out. Do I need to a) have the lock cylinder out, b) turn the lock set screw all the way out, then turn it back in a turn, c) pull the outside door handle out and hold it out while sliding the lock cylinder in, then release the door handle, then turn the lock set screw all the way in?

I just re-read the instructions below and realized that I did not unscrew the lock set screw all the way out and I will try that later, but, is it likely that something is damaged or out of place which is preventing the lock set screw from keeping the cylinder in? How does the lock set screw work, I can't see where it locks into the cylinder.

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Unhooking the lock mechanism:

On the end side of the door, pry off the black plastic cap above the lock mechanism screws. This cap covers the access hole for the lock set screw. (illustration)
Use a Torx T20 driver to unscrew the set screw. Unscrew it as far as it will go, then reinsert a few threads to keep the screw from falling out of its mounting.
Pull on the exterior door handle - with the door handle in this position, pull on the lock cylinder. It should slide out without much trouble. Set the lock cylinder aside. (illustration)

 

[Urlik]

Been along time since I pulled mine out but I think it's the pressure on the cylinder the "locks" it in place. I don't remember a notch or anything like that to hold it in.

 

[RCinSTP]

Thanks for the help Urlik, I think you are on the right track, it seems like the lock set screw pushes two curved pieces of metal against the cylinder, but I can't really see from the outside. I will take the door apart this weekend if I need to.

 

[Tomvw]

The clamp bit that secures the cylinder sometimes falls down inside the door if the screw is loosened too far, these links might help.

Door Lock Mechanism Repair (With Pics)
https://www.dropbox.com/s/7q6e8n9681nfcex/Door%20Lock%20Mechanism%20Repair.docx?dl=0

Door Lock Repair Spinning Barrel Lock Jammed - PassatB5

 

[RCinSTP]

Thank You Tomvw! I wasn't sure if there was a clamp type thing but I can see two parts that look like they might be two sides that clamp onto the cylinder and those parts are loose. I won't have access to the car for a few more days but when I do, I will open the door up and see what I find in there and report back.

 

[RCinSTP]

My problem is the same as in the thread at the link below. At the end of the thread it says: "- The ring has a lip on it - that lip goes towards the outside of the car"

Does anybody know which side goes towards the outside (A or B in the picture). Also, any tips on the instructions below (from the other thread).

- The ring is C-shaped - install the middle of the C first
- Lay it in the slot - install at a 45 degree angle so that the ends are away from the door (towards the inside of the car)
- Once the middle is in the slot, lay the clip into the door handle

http://www.passatworld.com/forums/b5-garage/257726-passenger-door-lock-how-do-i-put-back-together.html?postcount=5

 

[RCinSTP]

I figured it out. There is only one way that the thing in the picture above fits, it's with the A side towards the outside. I could not get it to fit using the steps described in the other thread but it was super easy to take the door handle off and then put that piece in place. Be sure to hold it in place by turning the set screw in enough to keep it in place while putting the door back together, then unscrew it to put the lock cylinder back in. The reason it fell of in the first place is because I unscrewed the lock cylinder set screw to far and left it unscrewed.