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Unread 04-01-2013, 07:53 AM   #1
super98lsc
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1999 WJ 
 
Join Date: May 2006
Location: Austin, TX
Posts: 1,414
Power Lock Servo Rebuild- W Pics/ Freebie!

Tired of weak/non functional locks? I posted a while ago about how to rebuild the window/lock motors without spending any cash. I had one lock servo left on the list to rebuild and just got to it over the weekend...

Drill rivets and remove lock servo / w bracket from door.
The actuator rod is held with rubber so it just pushed out of the hole, look inside you will see what I mean. (on my 90 at least)

Start by removing the 3 long 1/4 head bolts from the housing. Index the housing to the plastic case with a scribe, razor blade. You want to be able to clock the magnets back as they were. Then using channel locks gently wiggle the metal magnet/motor casing off the plastic gear case body. DO THIS OVER A CLEAN BENCH. There are 2 tiny little brushes in there that you dont want to lose, along with the associated springs.

Once you have that secured look at the end of the commutator and you will see the scored up worn ick that causes lack of good current flow to the stator/windings.

Remove the stator/shaft. I placed mine in my small drill press on lowest speed setting then resurfaced it using 1000 grit paper (NOTHING MORE ROUGH) or you will destroy it. You can also place the stator into a hand drill just be careful when applying pressure you dont rip through the paper and your finger tips. Ask how I know

In the pictures you can see the before and after. Also take note the brushes were worn unevenly so you can also lightly and (LIGHTLY) sand them flat with the 1000 grit so they will mate and make solid contact with the comm.

Next clean out all the hard old grease from inside the motor case, I used silicon spray to flush out the gear case and re-lubricate everything inside it. (oddly i found one of my servos to have a bent motor shaft causing the gear case to bind, i carefully straightened it out on a vice and works great now). I didnt like the rusty crap on the motor housing so I ran it on the bench grinder with a soft brass wire wheel then repainted it with the only paint I had left in the closet. Red makes it faster... ask the Honda guys.

Next just lay the case down and place both springs in the hole then pop in the brushes. I installed the comm shaft into the plastic side 1st then held it in place gently with a small thin flat head so the magnets wont lift it out as you slide the cover back over. The motor shaft is indexed so make certain you get it back on correctly. Also ensure you clock the metal case as it came off. (scribe mark from beginning) If you dont the lock servo could run backwards of the switch polarity. Same for window motors. Once assembled re-install in reverse order but also lubricate all the locking rod/actuator mechanisms in the door. At this point the locks should work like machine guns.

Lastly...Have beer... enjoy...

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Unread 04-01-2013, 08:10 AM   #2
super98lsc
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1999 WJ 
 
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More pix
dsc01471_800x600.jpg   dsc01484_800x600.jpg   dsc01485_800x600.jpg   dsc01488_800x600.jpg   dsc01490_800x600.jpg  

dsc01464_800x600.jpg   dsc01493_800x600.jpg  
__________________
www.mangierisrc.com
06-Corvette z51-6spd,b&b,K&N low miles.
77-Corvette Stingray 496 BBC/TH400 built 667hp+
===================================
00 WJ 4x4, 4.7 stroker, turbocharged,..lots more..
01 WJ 4x2 4.7v8 Limited (needs valve job)
90 Grand Wagoneer 401 Edelbrock Heads, Lunati .510/.527 FT Cam, Edelbrock RPM Air Gap, Holley HP 750, Thorley Headers, HEI, Electric Fan w Digital controller,4" lift 31x10.50 Goodyear Duratrac's on Pro-Comp Wheels,new interior, seats,seals,Alpine and JL full system, Remote HEI, Clifford 2 way with remote start,windows,tailgate.
96 Cherokee Country 4dr/2x2 White/Tan 3" Lift Sahara 18" Wheels 32.5"'s 99up head and intake- for sale soon!
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Unread 04-01-2013, 10:43 AM   #3
Saul32
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Location: Chicago, IL
Posts: 605
Super nice. Def need to do this to my doors asap.
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Unread 04-01-2013, 11:03 AM   #4
super98lsc
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1999 WJ 
 
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Location: Austin, TX
Posts: 1,414
Same basics work on the window motors as well. The only thing that will render them dead is brushes completely gone or the. stator is shorted out. If thats the case the motor wont run at all or blow fuses but if it "tries" to work then you should be able to renew it. My windows are quick like new. I also upgraded my main power feed from the battery to the remote starter relay on the passenger wheel well. Not certain what is was stock but someone had built a new 8ga for it. Simply not enough current capability. Replaced with a 4 Ga. Next up is to upgrade the 2 lines with the fuse links that run from that relay to the fuse box input inside the truck. Even though i measure 12.4v at the window motors on all 5 doors the current to them is not as strong as it should be. For example if I jump the window motors using jumper cables to the battery directly they run much faster. I re soldered the PO's half arsed hack job on the drivers door harness, but no change.
dsc01500_800x600.jpg   dsc01501_800x600.jpg  
__________________
www.mangierisrc.com
06-Corvette z51-6spd,b&b,K&N low miles.
77-Corvette Stingray 496 BBC/TH400 built 667hp+
===================================
00 WJ 4x4, 4.7 stroker, turbocharged,..lots more..
01 WJ 4x2 4.7v8 Limited (needs valve job)
90 Grand Wagoneer 401 Edelbrock Heads, Lunati .510/.527 FT Cam, Edelbrock RPM Air Gap, Holley HP 750, Thorley Headers, HEI, Electric Fan w Digital controller,4" lift 31x10.50 Goodyear Duratrac's on Pro-Comp Wheels,new interior, seats,seals,Alpine and JL full system, Remote HEI, Clifford 2 way with remote start,windows,tailgate.
96 Cherokee Country 4dr/2x2 White/Tan 3" Lift Sahara 18" Wheels 32.5"'s 99up head and intake- for sale soon!
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Unread 01-06-2014, 06:42 PM   #5
jamesmega
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1988 FSJ Wagoneer 
 
Join Date: Nov 2013
Location: College Park, MD
Posts: 48
I'm having problems with my external locks. I'd appreciate any help.

Both locks will lock the doors from the outside but not unlock them. I used some liquid wretch penetrating oil on the drivers side door and know the electric locks will lock and unlock that door. Haven't done anything with the passenger door yet. I'd appreciate any help how to reconnect any rod that might have displaced or if I need to replace the external door locks with new ones. Thanks.
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Unread 01-06-2014, 07:23 PM   #6
RockRollin
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May have to pull the door panel and look for mechanical damage or corrosion, could be interference on the actuator rods.
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Unread 01-07-2014, 12:57 PM   #7
super98lsc
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1999 WJ 
 
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Like Rock said pull the door panels. What happens is all the white lithium grease that the factory used in there 20+ years ago has dried solid and binds up all the mechanisms. Cleaning each part and re greasing it will make a huge change. Same for the inside door handles.
__________________
www.mangierisrc.com
06-Corvette z51-6spd,b&b,K&N low miles.
77-Corvette Stingray 496 BBC/TH400 built 667hp+
===================================
00 WJ 4x4, 4.7 stroker, turbocharged,..lots more..
01 WJ 4x2 4.7v8 Limited (needs valve job)
90 Grand Wagoneer 401 Edelbrock Heads, Lunati .510/.527 FT Cam, Edelbrock RPM Air Gap, Holley HP 750, Thorley Headers, HEI, Electric Fan w Digital controller,4" lift 31x10.50 Goodyear Duratrac's on Pro-Comp Wheels,new interior, seats,seals,Alpine and JL full system, Remote HEI, Clifford 2 way with remote start,windows,tailgate.
96 Cherokee Country 4dr/2x2 White/Tan 3" Lift Sahara 18" Wheels 32.5"'s 99up head and intake- for sale soon!
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Unread 01-08-2014, 07:23 PM   #8
jeepdaddy2000
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I could be wrong, but I believe those are standard GM style electric motors. Might be something to think about if you need to replace one or two, as there are a ton of them in the U pick yards.
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