rear lid release adjustment

Here is the write up on replacing the cable on a 328 which is similar. To remove the handle, you have to loosen the cable at the latch ends. You may not need to replace the cable, but here are the full instructions.

Repairing the cable is not too hard, but takes some patience and proper adjustment. I replaced mine last summer, since it was fraying at the cable end. You are lucky that the emergency cable opened it up. There are stories of failed main and emergency cables. Supposedly, the only solution is to break out a taillight or similar drastic means.

Remove the interior pieces around the latches. Three screws each. Look to see where it feeds through the latches, since you will have to accomplish this with the new cable. Study it to see how the cable nut trips the latch. DON'T close the lid until later. Get a good light and a small bowl to catch the cable nuts if they fall off of the cable ends. You will have to bend over and look at the latches upside down while making the repair and adjusting the cable nuts.

1. Get a new cable from a dealer. You can make one or get a bicycle shop to make one, but I went with the proven cable.

2. The cable frays where it enters the bodywork near the handle by design. I bought an extra cable for future use.

3. Lift the handle and remove the one screw that holds it in. The handle will come out and you can pull out the cable after you loosen the lock nuts at each latch.

4. Now you have the cable out and just the emergency cable going to the driver's side latch.

5. Attach the new cable to the handle with the nut and lock washer. You have to feed the entire thing through the hole to get the ring over the post with the nut and washer. Don't overtighten, since the handle is plastic.

6. I put some cable lube on the cable and fed it from the door to the first latch. Don't force it or you will kink the cable. I bought a third cable, since I kinked the first one and used the spare. As it comes out of the bodywork at the first latch, feed it through the latch and into the cable nut with the emergency cable.

7. The cable nut is what trips the latch when the cable is pulled, so push down the latch, and line up the cable nut with the piece that springs open the latch. If it is lined up, start feeding the cable through the metal line to the passenger latch.

8. At the passenger latch, feed it though the latch and put the cable nut on the end so it is in the same position to trip that latch's mechanism.

9. Now everything is in place and needs to be adjusted. The goal is to pull the cable and trip both lock nuts to open both latches. Also, the emergency cable needs to trip the driver's latch and pull the main cable to trip the passenger latch. If the cable broke between the latches or is too slack between the latches, the emergency cable does not work to open the passenger latch.

10. Replace the handle and screw near the door.

11. I grabbed the cable end at the passenger side and pulled it tight. You want a little tension, but not straining the cable. Tighten the passenger lock nut. With the lid open, press the passenger latch closed. Pull the handle and see if it unlocks and if the handle feels like it did before (not too tight, not too loose). Just a little pull, the cable lock moves, trips the latch, and the handle pulls a little more.

12. On the driver's side move the cable nut with both cables in it against the latch and tighten. Test it a few times.

13. With the lid open, push both latches closed and pull the handle to open both latches. Best is near simultaneous, with the passenger side maybe a hair sooner. Remember, the emergency cable doesn't help the passenger side if the slack is between the cables.

11. Test, test, test with the lid open. Do the latches release easily? Does the handle pull, release both latches, and have a little more pull left? Is the cable tight enough to release both latches, but not too tight that it binds making the bends? Are the lock nuts against the latch releases and tightened down so they do not slip?

12. Now close both latches and test the emergency cable with the lid open.

13. Replace the interior pieces. Lube the latches.


Not too hard, but scary the first time you close the lid with the new cable, because you are afraid it won't work.

 

Taking the two taillights out before starting might be a VERY Good idea......

 

Mule's guide is great. It's really very easy and not as complicated as explaining it sounds. I just did mine the other week - took 15'. Ordered the cable w.attached securing (pull-end) eye.

 

Yup!