95 Discovery 1 Door Actuator Repair
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Drifting
Joined: Jul 2018
Posts: 35
Likes: 3
From: Christchurch
95 Discovery 1 Door Actuator Repair
I believe the D1 actuator repair has been dealt with in the past. There is a mention on the site of a link with details, but this seems to have naturally dissolved. All the door actuators are losing potency, but before I dissect the back door unit with the Dremel, could someone please advise on any first-hand knowledge of the internal mechanics and experiences? Many thanks in advance. Regards Tony G
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Drifting
Joined: Jul 2018
Posts: 35
Likes: 3
From: Christchurch
Discovery 1 Rear Door Actuator
Thank you Gervin23. The image is the unit from my '95 D1. I wonder whether your '97 differs from this configuration. This unit appears to be joint sealed, I'm not sure, but would appreciate some input before proceeding with dismantling. cheers
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Drifting
Joined: Jul 2018
Posts: 35
Likes: 3
From: Christchurch
To continue:
Opening the D1 actuator unit was difficult. Using a small hacksaw on the elbow corner to create a small gap I was able to gently break the join with a screwdriver. On doing the same on the opposite side and moving the screwdriver along the joint line it (reluctantly) opened. The internal gearing was good but required a clean and re-lube. The motor operated as expected with the FOB switching. The actual fault was a broken return spring in the door latch mechanism. Extracting the latch/ lock mechanism out of the tailgate door is a lesson in patience. It does come out but only at a certain angle. One certainly needs proctologist hands as some clip fixtures are awkward. I would recommend photographing all the steps taken in sequential disassembling, so as to avoid later frustrations on mis-sequencing on reassembly. Replacing the broken spring is a simple job, provided one end of the spring is put in the round hole first then the other in the triangle hole. Cheers, Tony G
Opening the D1 actuator unit was difficult. Using a small hacksaw on the elbow corner to create a small gap I was able to gently break the join with a screwdriver. On doing the same on the opposite side and moving the screwdriver along the joint line it (reluctantly) opened. The internal gearing was good but required a clean and re-lube. The motor operated as expected with the FOB switching. The actual fault was a broken return spring in the door latch mechanism. Extracting the latch/ lock mechanism out of the tailgate door is a lesson in patience. It does come out but only at a certain angle. One certainly needs proctologist hands as some clip fixtures are awkward. I would recommend photographing all the steps taken in sequential disassembling, so as to avoid later frustrations on mis-sequencing on reassembly. Replacing the broken spring is a simple job, provided one end of the spring is put in the round hole first then the other in the triangle hole. Cheers, Tony G
Thread Starter
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Drifting
Joined: Jul 2018
Posts: 35
Likes: 3
From: Christchurch
These springs are the same. The supplier is Southern Four Wheel Drive Ltd, Christchurch, New Zealand. They had them made locally. Brick house quality. I would say with the NZ dollar in your favour, (UKP, USD, AUD) even with postage, the springs would be a better buy than the unknown. Cheers
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