PART A. INSTRUCTION SHEET FOR LOCK SERVICE PACK 5F1Z AA, XL2Z AC, XL1Z AB, F7SZ CB, F8OZ AB,

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1 5F1Z AA, XL2Z AC, XL1Z AB, F7SZ CB, F8OZ AB, F8LZ AB, KIT - 5F1Z AA. XL2Z AC, XL1Z AB, F7SZ CB, F8OZ AB, F8LZ AB, Item # Part Number Description Used in Package Quantity A SK 5F1A AA Instruction Sheet (48413) All 1 B Tumbler # 1 All 4 B Tumbler # 2 All 4 B Tumbler # 3 All 4 B Tumbler # 4 All 4 B Tumbler # 5 All 4 C Tumbler Springs All 8 D Cylinder Sub-Assembly XL1Z AB 1 2C5Z BB 1 F8LZ AB 1 D Cylinder Sub-Assembly 2C6Z BB 1 2C6Z BC 1 D Cylinder Sub-Assembly E Lock Case E Lock Case E Lock Case XL1Z AB 1 E Lock Case E Lock Case E Lock Case F8LZ AB 1 E Lock Case 2C6Z BB 1 E Lock Case 2C6Z BC 1 E Lock Case 2C5Z BB 1 E Lock Case F Grease Pack All 1 G Shutter Assembly All 1 H Shutter Spring All 1 I Shutter Cover (Black) XL1Z AB 1 2C5Z BB 1 I Shutter Cover (Stainless) XL1Z AB 1 2C6Z BB 1 2C6Z BC 1 I Shutter Cover (Stainless) I Shutter Cover (Stainless) F8LZ AB 1 I Cap Bezel Right Hand (Black) SK-5F1A AA SHEET 1 OF 6 Part # 48413AC

2 Item # Part Number Description Used in Package Quantity I Cap Bezel Left Hand (Black) I Cap Bezel J Gasket XL1Z AB 1 F8LZ AB 1 J Gasket 2C5Z BB 1 2C6Z BB 1 2C6Z BC 1 J Gasket K Spacer 2C6Z BC 1 L E-Clip All 1 M Detent Spring XL1Z AB 1 F8LZ AB 1 N Detent Pin XL1Z AB 1 F8LZ AB 1 N Detent Pin This Instruction Sheet is not an inspection document. This Instruction Sheet is used for several different lock service packages. As a result: Not all parts are included in all packages. Pictures may not represent actual parts included in package. A. Before the lock is removed from the installed location, record the orientations of the lock lever and anti-theft switch (if so equipped - Mustang). If the lock is in its normal position, note the direction at which the lever is pointing (forward, rearward, upward or downward of the vehicle). If the lock is not in its normal position, look at the back of the lock cylinder sub-assembly and note the direction at which the lock lever is pointing with respect to the drainage hole located at the bottom of the lock case (E). Note also the offset of the lever (refer to Figure 6). B. Carefully remove the E-clip (L) and disassemble the lock lever and white spacer (K) (if so equipped). Keep the E-clip (L), and lever, anti-theft switch and white spacer (K) (if so equipped) in a secured place until the new lock has been built and is ready to be installed in the vehicle. SK-5F1A AA SHEET 2 OF 6

3 SERVICE PROCEDURE: 1. Determine the matching key cut depth at each key station, any of the following three methods may be used to determine the key cut depth at each key station. 1a. Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table. (The selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter, Part No b. Use a key decoder to determine each cut height. A decoder may be included with the Rotunda Key Cutter, Part No or can be ordered separately through Rotunda Part No. 011 RMT61. Equivalent decoders are commonly available through the locksmith industry. (A key decoder is a plate with an elongated slot corresponding to the different key cut heights). 1c. Using the customer s key, measure the key cut depth at each key station (refer to Figure 1). Write down the key cut depths, in terms of the depth code, not the actual measurements of the depths, in the following order: Station 1 Station 2 Station 3 Station 4 Station 5 Station 6 Station 7 Station 8 X X 2. Verify that a shutter (G) is installed in the front of the lock cylinder sub-assembly (D). If not, then insert the shutter spring (H) into the round hole at the front of the lock cylinder (D) and the shutter (G) into the rectangular depression located at the front of the lock cylinder (D). 3. If required, insert the detent spring (M) into groove located on the interior surface of the lock case (E). 4. If required, insert the detent pin (N) into the groove located on the interior surface of the lock case (E). 5. Select the required tumblers (B) according to the key cut depths, for key stations 1, 2, 3, 4, 5, and 6. For example, if the key cut depths codes are , then use B5 for Station 1, B3 for Station 2, B2 for Station 3, B1 for Station 4, etc. and ignore Station 7 and Station Insert one tumbler spring (C) into each of the holes located at the end of the tumbler slots on the lock cylinder sub-assembly (D). 7. Insert the required tumblers (B) into tumbler slots in the proper orientation (refer to Figure 3) and in the sequence that match the key cut depths, for key stations 1,2,3,4,5, and Insert the key into the key hole and verify that all tumblers (B) are flush with the lock cylinder subassembly s (D) exterior surface. 9. With the key in the lock cylinder sub-assembly (D), apply the included grease (F) to the tumbler slots. 10. With the key in the lock cylinder sub-assembly (D), insert the lock cylinder sub-assembly (D) into the lock case (E). 11. Rotate the lock cylinder sub-assembly (D) within the lock case (E) at least ten (10) times so that the grease applied to the tumbler slots is distributed along the inner surface of the lock case (E) and the exterior surface of the lock cylinder sub-assembly (D). 12. Position the key in a vertical orientation and remove the key from the lock cylinder sub-assembly (D) while keeping the lock cylinder sub-assembly (D) within the lock case (E). SK-5F1A AA SHEET 3 OF 6

4 13. (Refer to Figure 5) to place the shutter cover (I) (depending on the cover originally installed) in the depression on crimping tool (Rotunda Tool number , refer to the instructions for the crimping tool). Place the lock case (E) on top of the shutter cover (I) (make sure that the lock cylinder sub-assembly (D) does not fall out of the lock case(e)). To secure the cover to the head of the lock case (E), use the swing arm on the crimping tool to crimp four tabs on the shutter cover (I). 14. If needed, select the proper door lock lever (consult catalog). 15. Assemble the anti-theft (if equipped) and then the lock lever in the orientations and directions recorded in steps A and B on page 2 (for set 2C6Z BC add spacer (K) instead of switch) (refer to Figure 6). When assembling the anti-theft switch to the lock, DO NOT rotate rotary part of the anti-theft switch with respect to the stationary part of the anti-theft switch or vice versa (refer to Figure 4). The anti-theft switch or spacer should be installed between the lock case and the lever. 16. Install the E-Clip (L) to the back of the lock cylinder sub-assembly (D) to secure the lever or spacer. Note that the tab on the E-Clip (L) should fit into the indentation on the back of the lock cylinder sub-assembly (D). (Refer to Figure 6) for proper orientation of the E-Clip (L). 17. Use the key to check the operations of the lock. 18. (Refer to Figure 7). Install the completed lock to the door. Place the provided gasket (J) between the head of the lock case (E) and the sheet metal 0.35 in 0.25 in (6.44)mm 0.20 in (5.18)mm (9.00)mm 0.30 in (7.72)mm STATIONS in (3.90)mm DEPTH CODES in (19.12)mm in (21.46)mm in (7.42)mm in in (9.76)mm (12.1)mm in (14.44)mm in (16.78)mm FIGURE in (5.08)mm STOP SK-5F1A AA SHEET 4 OF 6

5 (J) GASKET (E) CASE (M) DETENT SPRING (D) LOCK CYLINDER (I) SHUTTER COVER BACK FRONT (N) DETENT PIN (H) SPRING (G) SHUTTER FIGURE 2 HAND HELD PART OF THE KEY STATIONS SEE VIEW A (B) TUMBLERS (C) TUMBLER SPRINGS TOP (D) CYLINDER BOTTOM FIGURE 3 STATIONARY PART OF THE ANTI-THEFT ROTARY PART OF THE ANTI-THEFT NOTCH ON THE ROTARY PART SHOULD BE ALIGNED WITH THE GROOVE ON THE STATIONARY PART FIGURE 4 SK-5F1A AA SHEET 5 OF 6

6 FIGURE 5 (L) E-CLIP MUST LINE UP WITH THE NOTCH LEFT A RIGHT B (OPTONAL) (OPTONAL) (D) BACK OF LOCK CYLINDER SEE VIEW A (K) SPACER (L) E-CLIP VIEW A (K) SPACER (L) E-CLIP FIGURE 6 (J) GASKET (J) GASKET SEE VIEW A LOCK LOCK OUTSIDE OF THE DOOR INSIDE OF THE DOOR REAR VIEW VIEW A FIGURE 7 SK-5F1A AA SHEET 6 OF 6

PART A. INSTRUCTION SHEET FOR LOCK SERVICE PACK XW4Z CB, 5W4Z BB AND 4R3Z AA

PART A. INSTRUCTION SHEET FOR LOCK SERVICE PACK XW4Z CB, 5W4Z BB AND 4R3Z AA KIT, 5W4Z-5421991-BB AND 4R3Z-6321990-AB Item # Part Number Description Used In Package Quantity A SK 5W4A-5421991-BB Instruction Sheet (48387) All 1 B1 324341 Tumbler # 1 All 4 B2 324342 Tumbler # 2 All