Stuck boot lock on estates
 

I have a 240 GLT and 240 Se, on both of them I keep getting a problem with the boot lock sticking. This is an intermittent problem which sometimes clears itself, and other times I have to remove dog guard and clamber over to get to internal catch.

Often this seems to happen if the boot is locked with the central locking and you try to open with the key, it jams and then wont open with central locking either. once released it works fine for a few days then repeats the experience.

All advice welcomed.

Couple of potential causes
FIRST check that the actuating motor is moving the sliding bolt across and back. You will need to remove the rear trim panel. (two screws to release the inner pull handle surround, then using a thin broad screwdriver or similar 'pop' the clips around the outside edge of the trim and remove)
You will be able to see the drive motor and the slide. Make sure the slide is lubed with white grease or similar and is sliding OK.
If this all checks out ok then
SECOND and more likely is the failure of the wiring in the hinge which drives the central locking.
If when you lift the tailgate up and down you are making and breaking the circuit you will get intermittent operation. and in my own case recently the popping of the left hand sidelight and rear number plate light fuse.
If you find the hinge wiring to be the problem then see earlier posts from me with replies from Mike and others

BY the way it is worth spraying some rust inhibitoe into the bottom of the tailgate while you have the trim off.
This and the rear arches are the first places to corrode on the 240 estate. I use and swear by Dinitrol cavity wax spray
Richard

Check the release handle/button
 

With the earlier 240's, the release button in the tailgate handle has two extensions into the tailgate cavity. These are drilled and a pin sits in the right side unit and is slid into the hole in the left side when the key lock is in the unlocked position. Motion from depressing the release button transfers via the pin into the actual lock mechanism, releasing the lock and tailgate.

In the locked position, the pin is withdrawn and rests in the right side extension only. Because the pin is not engaged, movement from pressing the release button does not reach the lock mechanism, and the tailgate remains closed.

I have found on two occassions that left extension has had a crack propogated through it allowing it to take on a permanent bend, ensuring that the pin cannot slide into the hole, and preventing the opening of the tailgate.
Messing about with key lock and release in combination may overcome the allignment problem about 5% of the time.

Later model units use the same principle but with a different set of castings for the handle and release button, and the addition of a solenoid to provide alternative control of the pin position.

I would check the extensions on the release button for damage.

As I recall, the locking system on the 2-Series tailgate was prone to siezing up due to road dirt being sucked in. Give it a good clean out and things should get better.

I have just removed the central locking mechanism from the tailgate of the 240 GLT and found the internal plastic pieces were brittle and in several pieces.

If anyone has one going spare please PM me.