Lock Cylinder Non-Functional

NOTE: The following procedure applies to vehicles where the ignition lock is inoperative, and the lock cylinder cannot be rotated due to a lost or broken ignition key; the key number not known; or the lock cylinder cap is damaged and/or broken to the extent that the lock cylinder cannot be rotated.

Removal
1. Disconnect the battery ground cable.
2. Remove the horn cover and steering wheel.
3. Remove the trim shrouds. Remove the connector from the key warning switch.
4. Use a 1/8 inch diameter drill, drill out the retaining pin, being cautious NOT to drill deeper than 12.7 mm (1/2 inch).
5. Place a chisel at the base of the ignition lock cylinder cap, and using a hammer, strike the chisel with sharp blows to break the cap away from the lock cylinder.
6. Using a 3/8 inch diameter drill, drill down the middle of the ignition lock key slot approximately 44 mm (1-3/4 inch) until the lock cylinder breaks loose from the breakaway base of the lock cylinder. Remove the lock cylinder and drill shavings from the lock cylinder housing.





7. Remove the snap ring, washer, and ignition lock drive gear. Thoroughly clean all drill shavings and other foreign materials from the casting.
8. Carefully inspect the lock cylinder housing for damage from the removal operation. It any damage is apparent, the housing must be replaced.

Installation
1. Install the ignition lock drive gear, washer, and snap ring.
2. Prior to installation of the lock cylinder, lubricate the cylinder cavity, including the drive gear, with Lock Lubricant.
3. To install the lock cylinder, turn the lock cylinder to the RUN position, depress the retaining pin, and insert it into the lock cylinder housing. Assure that the cylinder is fully seated and aligned into the inter-locking washer before turning the key to the OFF position. This action will permit the cylinder retaining pin to extend into the hold in the lock cylinder housing.
4. Using the ignition key, ROTATE the lock cylinder to ensure correct mechanical operation in all positions.
5. Attach the key warning switch wire. Install the shroud by attaching with 2 screws.
6. Install the steering wheel and horn cover.
7. Connect the battery ground cable.
8. Check for proper ignition and accessory functions and verify that the column locks in the LOCK position.