ORIGINAL FULLEX GEARBOXES
The original Fullex lock gearboxes were made of a heavy-duty cast metal 20mm thick case in either a yellow passivated or grey finish and would have originally been attached to a faceplate of varying widths up to 24mm.
Each model although generic in size had multiple variations usually centred around the fixing lugs and anti-slam mushroom, for example, Case ‘B’ had 47 different variants.
Although only Type “A” gearbox is still produced it can be used to retrofit the majority of the other types.
It can be difficult to measure the backset correctly when the lock is in the door, a sure-fire way of telling if a lock is an old-style 39mm or the newer 35mm version is the width of the handles unless the handles have been replaced since the original fitting the backplate will be 40mm wide on the 39mm and 30mm or thinner on a 35mm backset.
Nightlatch Reversal
Step 1: Lift one handle up and one down at the same time.
Step 2: Then turn the handle to break the pin to reverse the nightlatch function (pressure may be required).
Step 3: Use with part number SPLITSPIN. Insert larger spindle on the inside and smaller spindle on the outside.
COMMON PROBLEMS
A large percentage of failed original Fullex gearboxes, break in the same place.
Generally speaking, these gearboxes are robust and hardwearing, however, the most common fault is a weak area of metal at the rear edge of the gearbox behind the follower assembly.
Incorrect or forceful use of the door handle can cause a spur on the rear of the follower assembly to impact this piece of metal, which is designed to stop the spur from over-rotating.
After time this weak corner of metal can bend, crack, chip or snap off altogether, allowing the spur to over-rotate and the night latch feature to malfunction.
This design fault is often the cause of malfunctioning locks and therefore many original Fullex locking mechanisms can be repaired by the replacement of the gearbox.
FULLEX TYPE A GEARBOX
- Only one of the original style Fullex cases in production
- Originally produced in 39 and 55mm backsets
- 55mm backset is no longer manufactured
- Top lug will have ‘A’ cast into the face
- Lug is 9mm deep
- Lift lever or split spindle function
- Can be used to retrofit other original style lock cases
Latch Reversal
Undo screw or screws in latch, remove and reinsert.
Nightlatch Reversal
The split spindle should be inserted in on the internal side 2/3 of the way in and 1/3 on the external side.
FULLEX TYPE B GEARBOX
- No longer in production
- Originally produced in 39 and 55mm backsets
- Top lug will have ‘B’ cast into the face
- Lug is 2mm deep
- Used Lift lever or split spindle function
- 55mm backset is no longer manufactured
Latch Reversal
Undo screw or screws in latch, remove and reinsert
Nightlatch Reversal
The split spindle should be inserted in on the internal side 2/3 of the way in and 1/3 on the external side.
Replacement
Use Type A gearbox to replace 39mm version.
FULLEX TYPE D GEARBOX
- No longer in production
- Originally produced in 39 and 55mm backsets
- Top lug will have ‘D’ cast into the face
- Lug is 7mm deep
- Used Lift lever or split spindle function
- 55mm backset is no longer manufactured
Latch Reversal
Undo screw or screws in latch, remove and reinsert
Nightlatch Reversal
The split spindle should be inserted in on the internal side 2/3 of the way in and 1/3 on the external side.
Replacement
Use Type A gearbox to replace 39mm version.
FULLEX TYPE E GEARBOX
- No longer in production
- Originally produced in 39 and 55mm backsets
- Top lug will have ‘E’ cast into the face
- Lug is 7mm deep
- Used Lift lever or split spindle function
- 55mm backset is no longer manufactured
Latch Reversal
Undo screw or screws in latch, remove and reinsert
Nightlatch Reversal
The split spindle should be inserted in on the internal side 2/3 of the way in and 1/3 on the external side.
Replacement
Use Type A gearbox to replace 39mm version.
FULLEX TYPE F GEARBOX
- No longer in production
- Originally produced in 39 and 55mm backsets
- Top lug will have ‘F’ cast into the face
- Lug is 7mm deep
- Used Lift lever or split spindle function
- 55mm backset is no longer manufactured
Latch Reversal
Undo screw or screws in latch, remove and reinsert
Nightlatch Reversal
The split spindle should be inserted in on the internal side 2/3 of the way in and 1/3 on the external side.
Replacement
Use Type A gearbox to replace 39mm version.
FULLEX TYPE G GEARBOX
- No longer in production
- Originally produced in 39 and 55mm backsets
- Top lug will have ‘G’ cast into the face
- Lug is 13mm deep
- Used Lift lever or split spindle function
- 55mm backset is no longer manufactured
Latch Reversal
Undo screw or screws in latch, remove and reinsert
Nightlatch Reversal
The split spindle should be inserted in on the internal side 2/3 of the way in and 1/3 on the external side.
Replacement
Use Type A gearbox to replace 39mm version.