So while working on the truck lastnight this exact same thing happens to me... turned the lock and snap, the key gets stuck 90*

Luckily I had the driver door lock from the donor on the shelf!

The pliers indicate where the ring broke - I will definitely be pulling the next driver door lock I find at the junkyard!!!

 

On second thought, I may even take the old part to a local machine shop to have it replicated..

 

Same exact thing happened to me in my 99' D1 the ring snapped. So I tried super gle and it held for about two days before breaking again. So I went to home depot and bought some aluminum stock. I traced the broken part out on paper then cut it out on the aluminum. Drilled a hole in the center, made a notch on the bottom and it worked.

Alternatively you can 3d print one someone was kind enough to public share these files so here they are.

https://www.thingiverse.com/thing:1306202

 

I've spent the last couple of months teaching myself CAD and designing the cam that fits inside this pawl, with the intent of having it printed w/ 3D printer. I finally got it done last week - then I see this!! Thank you mr4x4, I got one ordered this morning from a shop here in Utah and will be able to get my door panel put back together.
It was a good learning experience, though (the CAD program - 123 Design). I noticed several other Disco parts on thingiverse, the headlight pivots are next for me.

 

Awesome! Tell me how the 3d printed door lock parts work , I cut out the circle piece in aluminum and it's been working so far so good but 3d printed parts wouldn't be bad either. 😎

 

I got my cam from a local Utah printer in 3 days after ordering. $6.75! I smoothed the ID with a piece of Scotch-Brite and it fit together perfectly. I opted to have it printed in ABS after researching the options. I'll add some pics tonight for you - very pleased. Russ

 

Sorry for delays - I've "mis-placed" the little link off of the actuator... I do miss having my shop!! Russ

 

I use Autodesk's Fusion 360 for 3D modeling- great CAM integration and very intuitive. That being said, I believe a 3D model already exists for the part: https://www.thingiverse.com/thing:1306202

Others have pointed out that 3D printed plastics can perhaps not hold up to heat well and may not work long term in the door. I made my replacement one-off from aluminum tube and plate, machined and TIG welded together:



In a pinch, and my first repair, to prevent the glued ring from splitting, you can epoxy some metal around the ring- i used welding rod- and i also replaced the plastic tab with aluminum. It held up fine for a month until I decided to make the alu one.

 

Hi there- I have same problem but the file you've linked to no longer exists. Do you still have 3 print file somewhere?

Much appreciated!

 

Same thing happened to me. Wish you could just buy the little black ring for a couple of bucks. I tried to fabricate my own but it just didn’t work out. Ended up buying a new one from AB for $250☹️ It works great but it just sucks spending that much money on something that should be cheap. Obviously plenty of people have had this problem.