Ignition Switch: Service and Repair

1. Disconnect battery ground cable (two ground cables on diesel engines).
2. Turn lock cylinder key to Lock position.
3. On models with tilt steering, remove steering wheel as described below, then the tilt lever:
a. Disconnect battery ground cable (two ground cables on diesel engines).
b. From underside of steering wheel, remove screws attaching horn pad to steering wheel spokes.
c. Lift up steering wheel pad, then disconnect horn wires and electrical connectors from pad.
d. Remove steering wheel attaching bolt and damper, if equipped.
e. Remove steering wheel using steering wheel remover T67L-3600-A or equivalent, Do not use a knock-off type wheel puller or strike end of steering shaft, as damage will result.
4. Remove upper extension shroud by squeezing at six and twelve o'clock positions and popping free of retaining plate at three o'clock position.
5. On all models, remove steering column shroud halves.
6. Disconnect electrical connector from ignition switch.
7. Drill out break-off head bolts attaching switch to lock cylinder housing using a 1/8 inch drill.
8. Remove two bolts using an Ex-3 easy-out or equivalent tool.
9. Disengage switch from actuator pin and remove switch from vehicle.
10. Rotate ignition key to RUN position, then install switch by aligning holes on switch casting base with holes in lock cylinder housing. Replacement switch is provided in RUN position, minor movement of lock cylinder to align actuator pin with ``U'' shaped slot in switch carrier may be required.
11. Install new break-off bolts and tighten until heads shear off, approximately 35-50 inch lbs.
12. Connect electrical connector to ignition switch, then install steering column shroud halves.
13. On models with tilt steering, install upper extension housing and tilt lever, then the steering wheel as follows:
a. Position steering wheel on end of steering shaft, aligning mark and flats on steering wheel with mark and flats on steering shaft, and ensuring that straight ahead steering wheel position corresponds with straight ahead position of front wheels.
b. If equipped, install damper and align locators with hole in wheel hub.
c. Install steering wheel attaching bolt and torque to 23-33 ft. lbs.
d. Connect horn wires and electrical connectors, then install horn pad.
14. On all models, connect battery ground cable, then check ignition switch for proper operation.