Door lock w/correction

[Joe Yakubik <75363.2524@compuserve.com>]

From: Joe Yakubik
My 91 200 TQW had the same thing happen.  Does your alarm still engage from the
driver's side? If so then it is structural failure of a gear in your lock.
Brendan Rudack had a pretty good guess on the prices, mine was similar, but I
replaced it myself.  There was an aluminum/alloy gear that sheared off, this was
compounded (caused?) by the weather strip in the door being about one-half inch
too long.  With every lock/unlock cycle the old gear rubbed the weather strip
until it broke.  The repair is pretty straight forward if you have a Bentley
manual to guide you through it.  If you choose to do it yourself read all the
steps first!!!  They do not appear in chronological order. The replacement parts
are a lock cylinder (you will need to swap your old tumblers (?) over; no
problem, just do it in order and make sure you put them in from the correct
side.  The other part is a metal gear with plastic teeth.  I filed one edge of
the teeth (kind of like a *c*) to a taper because as it was manufactured it
caused two blunt edges to meet and gave my door handle a little *kick* each time
I opened the door.  The tapered section was not required to activate to lock.  I
also trimmed the weather strip back so the lock was smoother.  
Tools required (for 91 200):
Phillips screwdriver
4 (maybe 4.5) mm Allen wrench (for door handle)
Needle nose pliers
expanding ring pliers (not necessary, but makes it easier, only coupla $)
file (as necessary to taper gear)
diagonal wire cutters (to trim weather strip, if necessary, strong scissors?)
white spray grease (while the door's opened up, lube it)
flashlight
patience, a moderately flexible hand/wrist, and a work area large enough to open
the door all the way.
Time required: anywhere from one-half hour plus based on mechanical aptitude,
luck, and the benevolence of the Audi gods.  My personal technique to appease
them is a small blood sacrifice: when I have a few skinned knuckles, I know I'm
almost done.
Joe Yakubik

I almost forgot:  you may also need a Torx screwdriver.  I forget which size,
but the correct one is in my Craftsman tool kit.  Probably a # 15, 20, or 25.
It is needed to remove the screw that holds the outside (non-movable) part of
the handle guard to the door.  On my old VW this was a Phillips.  I don't know
if all Audis are Torx or not.  
One last thing.  The *pin* that holds the trim on the movable part of the handle
is shaped just like the toothpicks in swiss army knives.  You can remove the
door handle without removing this trim piece (it was a pain on my car) but be
prepared to scratch it if you don't remove it.  A piece of tape over it might
help.
One more really last thing.  I also used some packing tape to tape the foam
pad/protector back to the door when I was putting it back together.  The glue
that holds it on is a one time only deal.  You'll see what I mean if you choose
to do this.  Good luck!