omgzilla
19-09-2009, 06:12 PM
HOW TO REPAIR DC5 COIN POCKET!
This looks to be a common problem with the DC5! The 'lugs' that the pocket pivots on dislodge and the pocket won't shut properly or falls out completely.
Here's a simple DIY showing how to refit the pocket and repair it for good!
Disclaimer: The following is provided as a GUIDE ONLY, and neither myself nor Ozhonda take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!
--------------------------------------------------------------------------------------------
Coin Pocket (repaired):
http://img15.imageshack.us/img15/8535/1working.jpg
Reference:
http://img30.imageshack.us/img30/7089/referencea.jpg
--------------------------------------------------------------------------------------------
Tools and Materials Required:
- Worklight or Torch.
- Philips Head Screwdriver(s).
- Superglue.
If the lugs are missing you'll also need:
- 2x Small bolts/screws with a Counter-sunk head... Like these:
http://img3.imageshack.us/img3/7655/screws.jpg
Note: The bolts should be only 3-4mm in diameter and the 'thread' pitch should be 'fine' so that it doesn't bite into the pocket itself. The pocket may be hard to open/close your bolts are too thick. The bolts are simply used in place of the missing lugs - not used to actually 'bite' into the plastic.
--------------------------------------------------------------------------------------------
Instructions:
Step 1: Remove trims!
http://img524.imageshack.us/img524/7590/column.jpg
Remove the under steering column trim by turning the 2x retaining clips 1/4 turn counter-clockwise then pull outwards (from the bottom) and then downwards. Set trim aside so it doesn't get damaged.
----------
http://img198.imageshack.us/img198/6687/underdash.jpg
Turn the retaining clip 1/4 turn and remove under-dash trim. Pull trim downwards at end nearest to the drivers door, then set aside.
--------------------------------------------------------------------------------------------
Step 2: Remove coin pocket!
Stick your head under the dash and you'll see the 4x screws securing the pocket assembly.
http://img14.imageshack.us/img14/462/pocketremoval.jpg
I find it easier to lay the seat back, then lie down on the seat (up-side-down).
Remove all 4x screws, then remove the coin pocket assembly.
Tip: You can remove the 2x right side screws and just simply 'back-off' the left side ones and the pocket will slide out to the side - making life a bit easier when re-installing.
--------------------------------------------------------------------------------------------
Step 3: Re-assemble the coin pocket!
Place the pocket into the pocket housing and align the lug holes.
http://img4.imageshack.us/img4/6282/pocketreassemble.jpg
If you have the lugs - glue them into the holes, like so:
http://img185.imageshack.us/img185/8706/glued.jpg
Note: Only glue one end of the lugs into place. Either glue the lug to the housing or glue it to the pocket itself - the pocket needs to be able to rotate in the housing, so if you glue both ends of the lug it will render the pocket useless!
I found it easier to align the pocket in the housing then just 'dab' the superglue onto the outer end of the lug, then insert it into position.
Alloy some time for the glue to dry.
----------
If you don't have the lugs: Put some superglue on the tapered area of the bolt heads and then push them into the holes until they sit flush with the housing. If they're too long - file/grind some of the length off.
Alloy some time for the glue to dry.
--------------------------------------------------------------------------------------------
Step 4: Re-install the coin pocket spring!
First place the spring into the slots on either side:
http://img10.imageshack.us/img10/9806/springslots.jpg
Then press the middle of the spring upwards and into the holster:
http://img12.imageshack.us/img12/1951/holsters.jpg
Test that it works!
--------------------------------------------------------------------------------------------
Step 5: Re-install coin pocket assembly!
Screw the coin pocket assembly back into place re-using the 4x screws.
----------
Re-install under-dash trim, making sure to fit the backing of the trim into the guide on the firewall, as shown:
http://img43.imageshack.us/img43/7425/trimguide.jpg
...and take care with the clip nearest to the door (push up). Then refit the retaining clip by pushing up and spinning 1/4 turn - until secure.
----------
Re-install the under steering column trim by first placing the upper locating tabs in place, as shown:
http://img30.imageshack.us/img30/1391/locatingtabs.jpg
...then fitting the retaining clips by spinning 1/4 turn - until secure.
--------------------------------------------------------------------------------------------
Stand back, admire your handy-work and pat yourself on the back. You've just saved yourself $100!
http://img10.imageshack.us/img10/8103/pbeari.jpg
Enjoy!
This looks to be a common problem with the DC5! The 'lugs' that the pocket pivots on dislodge and the pocket won't shut properly or falls out completely.
Here's a simple DIY showing how to refit the pocket and repair it for good!
Disclaimer: The following is provided as a GUIDE ONLY, and neither myself nor Ozhonda take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!
--------------------------------------------------------------------------------------------
Coin Pocket (repaired):
http://img15.imageshack.us/img15/8535/1working.jpg
Reference:
http://img30.imageshack.us/img30/7089/referencea.jpg
--------------------------------------------------------------------------------------------
Tools and Materials Required:
- Worklight or Torch.
- Philips Head Screwdriver(s).
- Superglue.
If the lugs are missing you'll also need:
- 2x Small bolts/screws with a Counter-sunk head... Like these:
http://img3.imageshack.us/img3/7655/screws.jpg
Note: The bolts should be only 3-4mm in diameter and the 'thread' pitch should be 'fine' so that it doesn't bite into the pocket itself. The pocket may be hard to open/close your bolts are too thick. The bolts are simply used in place of the missing lugs - not used to actually 'bite' into the plastic.
--------------------------------------------------------------------------------------------
Instructions:
Step 1: Remove trims!
http://img524.imageshack.us/img524/7590/column.jpg
Remove the under steering column trim by turning the 2x retaining clips 1/4 turn counter-clockwise then pull outwards (from the bottom) and then downwards. Set trim aside so it doesn't get damaged.
----------
http://img198.imageshack.us/img198/6687/underdash.jpg
Turn the retaining clip 1/4 turn and remove under-dash trim. Pull trim downwards at end nearest to the drivers door, then set aside.
--------------------------------------------------------------------------------------------
Step 2: Remove coin pocket!
Stick your head under the dash and you'll see the 4x screws securing the pocket assembly.
http://img14.imageshack.us/img14/462/pocketremoval.jpg
I find it easier to lay the seat back, then lie down on the seat (up-side-down).
Remove all 4x screws, then remove the coin pocket assembly.
Tip: You can remove the 2x right side screws and just simply 'back-off' the left side ones and the pocket will slide out to the side - making life a bit easier when re-installing.
--------------------------------------------------------------------------------------------
Step 3: Re-assemble the coin pocket!
Place the pocket into the pocket housing and align the lug holes.
http://img4.imageshack.us/img4/6282/pocketreassemble.jpg
If you have the lugs - glue them into the holes, like so:
http://img185.imageshack.us/img185/8706/glued.jpg
Note: Only glue one end of the lugs into place. Either glue the lug to the housing or glue it to the pocket itself - the pocket needs to be able to rotate in the housing, so if you glue both ends of the lug it will render the pocket useless!
I found it easier to align the pocket in the housing then just 'dab' the superglue onto the outer end of the lug, then insert it into position.
Alloy some time for the glue to dry.
----------
If you don't have the lugs: Put some superglue on the tapered area of the bolt heads and then push them into the holes until they sit flush with the housing. If they're too long - file/grind some of the length off.
Alloy some time for the glue to dry.
--------------------------------------------------------------------------------------------
Step 4: Re-install the coin pocket spring!
First place the spring into the slots on either side:
http://img10.imageshack.us/img10/9806/springslots.jpg
Then press the middle of the spring upwards and into the holster:
http://img12.imageshack.us/img12/1951/holsters.jpg
Test that it works!
--------------------------------------------------------------------------------------------
Step 5: Re-install coin pocket assembly!
Screw the coin pocket assembly back into place re-using the 4x screws.
----------
Re-install under-dash trim, making sure to fit the backing of the trim into the guide on the firewall, as shown:
http://img43.imageshack.us/img43/7425/trimguide.jpg
...and take care with the clip nearest to the door (push up). Then refit the retaining clip by pushing up and spinning 1/4 turn - until secure.
----------
Re-install the under steering column trim by first placing the upper locating tabs in place, as shown:
http://img30.imageshack.us/img30/1391/locatingtabs.jpg
...then fitting the retaining clips by spinning 1/4 turn - until secure.
--------------------------------------------------------------------------------------------
Stand back, admire your handy-work and pat yourself on the back. You've just saved yourself $100!
http://img10.imageshack.us/img10/8103/pbeari.jpg
Enjoy!