Another functional trunk. Sorry.... dealership!!
Well, nice day in NH and decided to attempt to repair trunk actuator with Clint's 3D printed delivery. My symptoms were: grinding noise when press trunk release latch and also when attempting to open manually with key; NO manual unlock working via key.
Inspected and found that the long actuator rod had become disconnected from the rear of the key cylinder (used for manual open). No broken parts there so re-attached and verified manual operation of opening trunk with key ONLY.
Of course since I had Clint's 3D parts in hand, I had to attempt the actuator repair. Not too shabby of a fix. Thanks to ALL who had any input, photos, tips and tricks.
I would DEFINITELY agree on ALL of the below items:
--> Removing the 3 phillips head screws + 1 electrical connection and take out the trunk latch along with the actuator assembly (4 13mm screws + 1 electrical connection) since they are held together via a rod and some plastic linkage parts (would not want to damage them); don't forget to disconnect the small greenish latch that attaches the long actuator rod to the rear of the key cylinder behind the passenger side tail light.
--> Sanding down the 3D printed piece from Clint until it is just slightly thicker than the original broken piece. I did not sand the 'detent' side at all to avoid any issues with the spring loaded piece not seating correctly. Just sand a little at a time because you can't add it back on if you take too much off, but we all should know that by now. If you don't shave enough when you go to perform the TEST mentioned below all you will hear is a click and NO motion.
--> After part has been replaced and actuator re-assembled, test manually by hand; works best to have actuator, trunk latch and actuator rod in lap while seated to perform this motion. Grab the long actuator rod and move back and forth left to right and ensure smooth full range movement as well as motion in the linkage that connects to the trunk latch assembly.
--> Test before installing: WITH TRUNK OPEN, and both assemblies not installed but held gently in hand, long rod to the right (while leaning over spare tire area) and press the trunk release button with your free hand to verify smooth movement. I made the mistake of installing and no worky after I had already closed the trunk. Made it a real pain to open....ANYWAYS! If you don't just hear a click and the movement is good, go ahead and re-install actuator, trunk latch and long actuator rod (snap rod in place). Make both electrical connections and tighten all bolts. Leave trunk open and perform same 'push the release button' and visually verify long actuator rod motion. Sweet. Now close the trunk and test. Can also test the manual key method. Re-install everything else you removed.
Go for a test drive. Just had to say that; like we need an excuse!
Well, I hope this wasn't too boring and helps. I didn't take any pics because all of the necessary ones are already present in this thread. Once again, thanks to ALL!!
