Removing the Door Lock
The door lock on the Fiesta (Photo 15) looks very much like those found on many other new cars where the lock is held in place by a single screw that can be accessed from the edge of the door. This is in fact the case, but the lock on the Fiesta is located further from the edge of the door than on most vehicles.
The access hole to remove the lock is covered by a plastic plug (Photo 16). Unlike a lot of other cars that have this type of set-up, the plug on the Fiesta is relatively small and made of a harder material. This plug is almost impossible to remove with just your fingernails.
In order to reduce the possibility of scratching the paint, I found that if I pushed in hard on the center of the plug, I could slip a knife blade under the raised edge of the plug, in this way I could easily pry the plug free without worrying about scratching the paint. (Photo 17)
After the plug has been removed, you should be able to see a shiny plate through the opening that has a small hole in it for an Allan wrench. At first, I assumed that the Allan wrench would need to be a metric size, but was surprised to find that it required a 7/64” SAE Allen wrench. The wrench also needs to be relatively long in order to reach the screw because the door lock sets back so far from the edge of the door. (Photo 18) I had to turn the wrench 26 full turns in order to release the lock. As I was loosening the screw, I was constantly afraid that I was going too far and that the screw was about to fall down inside the door. As it turned out, this was a needless worry because the screw is held in place very well.
Once the screw has been loosened sufficiently, the lock will pull out of the door easily (Photo 19). There are no cables or linkage rods connected to the lock that need to be disconnected. At this point, you can take the lock to the workbench for service.
In Photo 20, you can see the socket that the lock fits into and the lock retainer mechanism fully retracted to release the lock. The lock retainer is a “U” shaped bracket that slides into two slots in the lock housing. Loosening the screw pulls this bracket toward the edge of the door, allowing you to remove the lock once the bracket has moved far enough.
In photo 21, I have re-tightened the retaining screw with the lock removed so that you can see where the retainer rests when the lock has been re-installed. Personally, I like this type of retainer and think it will do a very good job of holding the lock in place. More importantly, it doesn’t look like this retainer will fall inside the door while you have the lock out like on some vehicles.
One quick note on the door handle though, just as on the new Camaro, the handle will pull completely out of the door if you pull on it while the lock is removed. Make sure that while you have the lock out that no one messes with the handle. I left the Allan wrench in place and gently closed the door until the handle of the Allan wrench was against the body of the car while I was working on this one.
Disassembling the Door Lock
The painted cover on the lock cylinder would be easy to scratch while working on the lock, so the first order of business is to remove it for safe keeping. The cover, like that on the new GM door locks is plastic and snaps into place on the lock housing. (Photo 22)
On the edge of the lock cover that is normally against the handle, there is a rectangular opening that fits over a ramp on the side of the lock housing (shown in Photo 23). A little careful prying between the lock and the cover at this point will allow the cover to come off the lock.
On the opposite end of the cover, a small tab that fits over the end of the lock housing. (Photo 24) Once the flat edge of the cover is loose, sliding it toward the tapered end of the lock will allow it to come free. Be sure to put the cover in a safe place while you work on the lock.
The new Ford Fiesta uses the new high-security side-milled lock system that Ford plans to phase in worldwide. It also has a transponder system that is essentially the same as other Ford products.
These new Strattec high-security 2-track locks are intended to become the standard lock system for future GM vehicles.
All four use the GM Z-Keyway system and the “Circle Plus” transponder system. All can be programmed with the standard GM on-board programming procedure, which takes 30 minutes.