Without Key

The following procedure applies to vehicles where the ignition lock is inoperative or lock cylinder cannot be rotated due to broken or missing ignition key and the key number is unknown, or the lock cylinder cap is damaged and/or broken so that lock cylinder cannot be rotated.

Fig. 5 Removing Ignition Lock Bearing Retainer:

Fig. 6 Removing Ignition Lock Bearing:

Fig. 7 Ignition Lock Drive Gear:

REMOVAL

1. Disconnect battery ground cable, then remove steering wheel as described below. Ensure steering wheel is in full up position on models with tilt steering.
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.
2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing.
3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud.
4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission.
5. Lift top half of shroud from column.
6. Punch lock cylinder retaining pin using a 1/8 inch maximum diameter prick punch, then drill out retaining pin using a {1/8} inch diameter drill, to a depth of 1/2 inch maximum. Use care not to damage cast housing when drilling out retaining pin.
7. Place a chisel at base of ignition lock cylinder cap, then strike chisel with sharp blows using a suitable hammer to break cap away from lock cylinder.
8. Using a 3/8 inch diameter drill, drill down middle of ignition lock key slot approximately 1 3/4 inch until lock cylinder breaks loose from steering column cover casting, then remove lock cylinder and drill shavings from base of cover cast housing.
9. Remove white plastic bearing retainer by inserting a suitable tool with a 90° bend on tip between bearing retainer and bearing and prying upward, Fig. 5. Note position of bearing retainer prior to removal.
10. Insert tip of a suitable screwdriver into double-D slot of bearing, Fig. 6, rotate 90°, then remove bearing.
11. Remove lock drive gear, Fig. 7, noting relationship of lock drive gear to rack teeth.

INSTALLATION

1. Lubricate and position lock drive gear in base of lock cylinder housing in same position as noted during removal. Position of lock drive gear is correct if last tooth on drive gear is meshed with last groove on rack.
2. Position bearing in lock cylinder housing, insert tip of screwdriver into double-D slot of bearing, then rotate bearing 90°.
3. Press white plastic bearing retainer into lock cylinder housing, ensuring retainer is in original position, then press firmly to snap into place.
4. Line up flats of drive gear with flats of washer by pulling down on column lock actuator. This will place actuator in RUN position.
5. Lubricate lock cylinder with suitable grease, then turn lock cylinder to ON position and depress retaining pin.
6. Insert lock cylinder into housing in flange casting, ensuring that tab at end of cylinder aligns with slot in ignition drive gear.
7. Turn key to OFF position, allowing cylinder retaining pin to extend into cylinder casting housing hole.
8. Rotate lock cylinder to all positions, ensuring cylinder is operating properly.
9. Connect lock cylinder electrical connector to horn brush electrical connector.
10. Position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in lowest position to aid assembly on vehicles with automatic transmission.
11. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half.
12. Install shroud retaining screws and torque to 18.5-25.6 inch lbs.
13. On models with tilt steering, install steering column collar by pressing on top and bottom while installing on column.
14. Install tilt lever and torque to 2.2-3.6 ft. lbs.
15. On all models, install 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.
16. Install lower dash panel trim cover, then connect battery ground cable.
17. Check for proper start in P and N, and ensure that vehicle cannot be started in D or R positions and steering wheel locks in LOCK position.