How do you remove an AL lock from a door?

AL-Series and discontinued D Lever-Series locks use castle nuts to hold the chassis to the spring cages and to keep the chassis positioned in the door. This causes confusion at times when the lock is being removed from the door because the castle nut is on the spindle hub, hidden by the spring cages, and the person trying to remove the lock does not know it is there. The typical complaint is that the mounting screws have been removed but the lock still cannot be removed from the door. The castle nut must first be removed before the lock can be removed.

A castle nut wrench, the tool shown in Figure 1, is shipped with the lock for ease of installment and removal and can be purchased from Schlage (part number 40-017).


Figure 1: Removing the castle nut on an AL-Series lock.

Removal of the lock WITH a castle nut wrench. 


Step 1: Remove the inside lever by using a pin wrench. See Figure 2.
Step 2: Remove the driver, driver cap, and rose. See Figure 2.
Step 3: With the mounting screws firmly in place use the castle nut wrench to remove the castle nut, see Figure 1.
Step 4: Remove the mounting screws and spring cage.
Step 5: Pull on the outside lever to remove the chassis from the door.
Step 6: Remove latch.

NOTE 1: It is important to have the mounting screws firmly tightened to try and relieve the pressure on the castle nut, otherwise it will be very difficult to remove the castle nut.


Figure 2: Removing inside trim.

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