The post for "Power door locks fixed!" is pretty well spot on.
I pretty much followed it to a tee, and learned a few tricks along the way. I won't repeat the procedure, but I do have a few things to add to it.
TOOLS NEEDED: 9/64" drill bit, tiny flatblade screwdriver,(eyeglass), 1-1/4" putty knife, screwdriver that fits screws used to re-assemble actuator case, air compressor with blow gun, WD40, and tin foil.
#8-32 SCREWS NEEDED TO RE-ASSEMBLE 4 ACTUATOR CASES: 20 - 1/2" for most screws, 8 - 3/8" for replacing rivets, and 4 - 1" for thick part of case. You'll need half as many screws for two-door models.
I used a 9/64" drill bit to drill halfway through the case from both sides, being careful to keep drill straight with plasic pins, and not wander off to the side. I centered it on the '"mushroom head" on the one side of the case, and used the pilot holes on the other side of the case as a guide. I used the same bit to drill out the rivets, and eventually had all the holes drilled all the way through the case with this bit. Then, using a putty knife, carefully pry the case apart, and pick out any plasic shavings that may have gotten inside the case. Use the putty knife to break off any remaining plastic rod left in the case.
I re-distributed the grease already in the case to pivot points, and gears, using the tiny screwdriver. I also used the tiny screwdriver to pry the little metal tabs on the motor, and remove the brush housing.
Once the motor was apart, I used WD40 and compressed air to clean the brushes, and the commutator contacts on the motor, being carefull to hold my finger over the end of the commutator shaft, and retain the tiny plastic washers that are on it. remove the resistor thingamabob from the brush housing, wrap it with foil, re-assemble motor, re-install it in the actuator housing, and re-assemble housing with screws listed above. Everything will only go together one way, none of the screws will need to be cut, and you should now have a working actuator! Clip the assembled actuator on to the door lock mechanism, plug it in, try it, and prepare to be amazed!
I was so stoked. This little trick saved me $189.00 for 3 actuators, and isn't at all difficult to do. I would highly recommend it to anyone with dead or dying actuators.
Big thumbs up to whoever took the time to do this for the first time, and share it with the rest of us!
