How to Replace the Multipoint Lock in a Wooden Atrium Door

This is a multipoint lock with 5 locking points (a spring latch, two rollers and two shootbolts) and a backset of 28mm (measured from the face of the lock to the middle of the cylinder).

The Ferco 528 lock is still being manufactured, although there have been some changes, and the new locks cannot be directly installed in older Atrium doors without some modifications being made.

This article will guide you through the process of replacing an old-style Ferco 528 lock (part #499047599) with a new-style (part #4990475).

Summary of Steps (Detailed Steps to Follow):

1. Remove trim.
2. Remove lock from door panel.
3. Grind rivets off new lock.
4. Trim new lock to fit in door panel with shootbolt tip.
5. Check new lock in door to see if mortise needs to be deepened.
6. Install new lock body in door.
7. Attach shootbolt tip.
8. Break off rollers.
9. Test operation of lock.
10. Reinstall trim, using new spindle with brass sleeves.

Replacement Notes:

• Roller positions are different on original lock than on replacement lock. In the replacement guide below, we advise that the rollers be removed and the lock be used with just shoobolts for the easiest replacement. Skilled homeowners may opt to instead re-position strikeplates and re-drill mortises for rollers.
• The spindle used with the original lock is 8mm in diameter. The new lock uses a 7mm spindle. In order for the original handles to work with the new lock and spindle, brass sleeves (included with purchase of replacement kit #4990475) need to be affixed on either end of the spindle so handles sit securely in place.

Detailed Steps to Replace Original Atrium Multipoint Lock:

1. Make sure door is unlocked (push handles down).
2. Unscrew cylinder screw from door edge. Screw is located approximately 5 inches down from the latch. Once screw has been removed, remove cylinder through interior side--if cylinder does not easily come out, rotate knob until cam is facing down and cylinder can be removed.

3. Remove handles and escutcheon plates. To remove handles, loosen set-screw on lever on interior side of door, and pull lever off spindle. Next, remove the exterior handle and spindle together. Unscrew escutcheon plates to remove from door.
4. Lock runs entire length of vertical edge of door. Remove all screws and remove multipoint lock from door edge.
5. Lay old lock next to replacement lock, lining up latches, cylinder holes and lock bodies. Make sure both locks are disengaged (shootbolt tips retracted). Locks will not be the same length.
6. New lock needs to be trimmed to fit in the door. Lay new shootbolt tips so top of top shootbolt lines up with original lock top and bottom of bottom shootbolt lines up with original lock bottom.
7. Mark on new lock where the difference must be trimmed from either end so lock fits in door with shootbolt tip attached. Note: Do not trim shootbolt tips; only main lock can be trimmed.

8. Clamp new lock to sturdy surface and carefully use a hacksaw to trim where marked. Note: This step requires caution and knowledge of safety procedures. Watch fingers and keep children away. Metal will be hot during and after cutting. Do NOT use a table saw or other powered device, as metal will change colors.

9. Use a file, sandpaper or a sander to smooth cut edge of trimmed extension piece.
10. Slip newly-trimmed lock body into mortise in door edge and hold up extension to double-check that length is correct.
11. Also note whether or not the lock faceplate is flush with the edge of the door or if it sticks out. The replacement lock is slightly deeper in some parts than the original lock, but it will depend on how your door was manufactured originally as to whether or not your lock will fit without adjustment.
12. If lock is not flush with edge of door and needs to be modified, use a hammer and chisel to carefully and slowly deepen the mortise where needed.

13. With replacement lock back out of the door, note roller locations on replacement lock. There is one mid-way between the top of the lock and the latch and one mid-way between the bottom of the lock and the latch. From the back of the lock (not the front faceplate that shows once lock is installed), grind off both rivets holding these rollers in place. Do not remove rollers yet.

14. Place main lock body (shootbolts detached) into mortise.
15. Attach shootbolts to lock by fitting alligator teeth of lock backplate into connectors on shootbolt tips. Use fingertips or a screwdriver to slide connector plate over gap between main gear and shootbolt. Note: Shootbolts have a plastic rivet for shipping purposes that will break off when lock is engaged the first time.

16. Screw lock in place at two or three points. Stick handle with spindle into lock and check the operation with the door open. The shootbolts should engage when the handle is lifted; turning the thumbturn should deadbolt the latch and secure the shootbolts in the extended (locked) position.
17. If the lock functions properly, unlock the mechanism and tighten all the screws running up and down the length of the faceplate.
18. Reinstall the cylinder, escutcheon plates and handles. Note: A new 7mm diameter spindle and two brass sleeves are included when replacement kit #4990475 is purchased. You will need to re-use or puchase new handles, cylinder and escutcheon plates.