749 (Class 80 DTS) - Secondary Door Locks Control Panel Removal

This article details the removal of the Secondary Door Locks Control Panel from the non-driving end of 749

Removal

1. Remove bolts securing control panel to frame pull panel carefully forward to access pneumatic connectors on the bottom edge of the panel.
2. Disconnect each of the pneumatic lines on the left hand side - each line has unique colour so is readily identifiable:
   
3. Disconnect each of the pneumatic lines on the right - this comprises two green and three yellow tubes which must be labelled - there are numbers against each port on the panel.
   
4. With the pneumatic tubes disconnected the panel can be drawn further out to gain access to the electrical connection at the top of the panel; pull the retaining clip back and withdraw the plug from the panel. The panel may now be removed.
5. The panel was secured to two u-profile rails, one to the left and one to the right. Each of these can now be unbolted (10mm head) and removed. Note the writing on each rail can be used to identify left and right.

   

   Left Rail

   

   Right Rail

6. With the two rails remove the bolts (10mm head, spanner required owing to lack of clearance) holding the steel housing can be removed and the housing removed.
7. Remove the corner trim between the wall panel and the ceiling, with the control panel removed it's now possible to get an impact driver onto the screws but even then 4 screws had to be drilled out. The trim had become stuck to both the panel and ceiling over time and had to be carefully prised away with a wide scraper so as not to crack it.
8. Remove the trim from the underside of the panel
   
9. Remove the screws holding the edge of the panel to the door frame.
10. Remove the screws holding the door strap to the body of the vehicle.
11. Very carefully pull the panel out, down and remove - pay particular attention to the edge adjacent to the door to ensure it does not get damaged.

Possible Work To Be Done Prior To Reassembly

• One of the screw heads securing the top corner trim split when drilling out and nicked the trim, this could easily be repaired with a small amount of polyester filler or resin.
• There are some pre-existing cracks in the trim - it might be possible to reinforce this area from behind with a strip of fibreglass tissue and some resin and then to rub down the re-spray the surface if it's cosmetically unacceptable.
• The surface of the control panel housing has corroded with rust now showing through the paint - a quick rub down, prime and respray should fix it.