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[05omegav6]

Looking at the guide, a couple of questions...

1. have tried stripping and refitting the brass bits, sounds like the first two aren't quite seated correctly 

2. on reassembly, did you push the sprung pin in to enable the lock barrel to turn in the housing so that the sprung pin clicks onto its track?

[Shackeng]

..... The numbered brass bits are all as removed and double checked.  ....

You sure?  It does seem like a tumbler or two aren't fitted correctly  you could just dress the protruding bits off with a file 

New tumblers aren't expensive though ..... I've got the web address of a place near Liverpool at home - but I'm at work now

Thanks  Andy, I've now triple checked, and they are defo correct. I'll try the dressing idea, although they are quite proud, one two others are also slightly proud. Am i correct that with the key in, all tumblers should be more or less flush?

[05omegav6]

Are you not to hold them flush whilst inserting the key? Dressing will alter their dimensions, which might have consequences

[Andy B]

..... Am i correct that with the key in, all tumblers should be more or less flush?

Yes. 

[Andy B]

Are you not to hold them flush whilst inserting the key? Dressing will alter their dimensions, which might have consequences

That's what Chris wants  ...... there are worn tumblers & worn sections of key and so they are protruding a bit. 

[Shackeng]

You can see the 2 nearest the key are about 1.5mm proud. I can get the inner into the barrel, but even though depressed by the key they are catching the internal edges - I think

[05omegav6]

Reading the guide, it suggests holding them flush before inserting the key

Are the springs seated correctly

[Shackeng]

Reading the guide, it suggests holding them flush before inserting the key

Are the springs seated correctly

I can only assume so as with the tumblers removed the ends are all level. The key wont go in unless they are flush, and I can get it in to the tumbler section OK, it just won't turn in the outer.

[Kevin Wood]

Are you sure the last 2 haven't been swapped?

If not, guess they or the key have worn. That's probably why you had a sticky lock barrel in the first place?

[Shackeng]

They're definitely in the same position as removed. Both keys show the same symptoms, and as other tumblers are slightly proud, and more likely to have worn (brass) I think I need to replace them all. There is just the nagging feeling that as the key did, mostly, work OK before my efforts, I may still be doing something wrong, but for the life of me I cannot think what, as I was most meticulous to reassemble correctly.

[Shackeng]

..... The numbered brass bits are all as removed and double checked.  ....

You sure?  It does seem like a tumbler or two aren't fitted correctly  you could just dress the protruding bits off with a file 

New tumblers aren't expensive though ..... I've got the web address of a place near Liverpool at home - but I'm at work now

Thanks Andy, PM the address if you can, thinking about it, the car has done 120K, but, and a big but, mainly journeys of 20 miles or so. Therefore the key has been used much more than normal, and no doubt the tumblers are fairly worn.

[omegod]

You already have some near new tumblers....in the glove box lock  !  if it's the original that is   

[Broomies Mate]

You already have some near new tumblers....in the glove box lock  !  if it's the original that is 

Beat me to it! 

[Shackeng]

Good call, does my pfl have a glovebox lock, if so I've never used it, but it should be original, I bought the car at 5k 14 years ago.

[Shackeng]

Looking at the guide, a couple of questions...

1. have tried stripping and refitting the brass bits, sounds like the first two aren't quite seated correctly 

2. on reassembly, did you push the sprung pin in to enable the lock barrel to turn in the housing so that the sprung pin clicks onto its track?

Sorry Al, I should have replied earlier.

1. Tumblers are seated OK otherwise key will not pass through them.
2. Unable to replace plunger as key will not turn to allow it to be replaced.