Ignition Switch Lock/Steering Lock - Difficult Operation
Article No.93-3-9
February 3, 1993
^ IGNITION SWITCH - DIFFICULTY IN FINDING THE LOCK POSITION AND REMOVING THE KEY
^ IGNITION SWITCH - ROUGHNESS OR EXCESSIVE EFFORT IN TURNING THE KEY FROM RUN TO START POSITION
^ IGNITION SWITCH - SOME ACCESSORIES DO NOT OPERATE AFTER KEY RETURNS FROM START POSITION
FORD:
1990-93 CROWN VICTORIA, TAURUS
LINCOLN-MERCURY:
1990-92 MARK VII
1990-93 GRAND MARQUIS, SABLE
1991-93 CONTINENTAL, TOWN CAR
This TSB is being republished in its entirety to update technical information, including a new grease procedure for vehicles built before 11/01/90 which include the 1990 Mark VII, 1990 Grand Marquis and 1990 Sable.
ISSUE:
The following ignition switch/lock cylinder assembly related conditions may be experienced from time to time. They are highly intermittent and may or may not be able to be duplicated at the service facility.
^ Difficulty in finding the key lock position and/or difficulty in removing the key from the lock cylinder.
^ Roughness and/or excessive effort in turning the key from RUN to START position.
^ Key does not fully return from START to RUN after starting vehicle. This allows the vehicle to be driven without some accessories functioning.
ACTION:
Replace the ignition switch assembly and ignition lock cylinder assembly. Refer to the following procedure for service details.
IGNITION SWITCH REPLACEMENT
1. Disconnect the battery ground cable and air bag backup supply.
2. Remove RH and LH lower mouldings from the instrument panel by pulling up and snapping out the retainers (Town Car, Crown Victoria, Grand Marquis only).
3. Remove the instrument panel lower trim cover.
4. Remove the tilt lever (if so equipped) by unscrewing it from the column.
5. Rotate the ignition lock cylinder to the RUN position. Using a 1/8" (3.175 mm) drift, depress the lock cylinder retaining pin through the access hole and remove the lock cylinder.
6. Remove the retaining screws from the lower shroud and remove the upper and lower shroud. On Taurus/Sable and Continental vehicles only, remove the four (4) nuts retaining the column skid plate.
7. Loosen the screw securing the harness to the switch and connector. Separate the wire harness from the ignition switch assembly.
8. Remove the two (2) screws securing the ignition switch to the column and remove the ignition switch.
9. When installing the new ignition switch, the switch alignment pin will be in the RUN position.
a. Align the pin on the switch with the slot in the lock/column assembly, Figure 1.
b. Position the slot in the lock/column assembly with the index mark on the casting.
c. Install and tighten two (2) retaining screws to 5-8 lb.ft. (7-11 N-m).
d. To assemble, reverse Steps 8 through 7.
NOTE:
TIGHTEN THE CONNECTOR RETAINING BOLT TO 0.8-1.3 N-m (.6-.7 LB.FT.).
Special service ignition lock cylinders with partially cut keys are available and can be installed using the following procedure.
IGNITION LOCK CYLINDER ASSEMBLY REPLACEMENT PROCEDURE
1. Remove the ignition lock cylinder. Refer to the appropriate 1991 Car Service Manual, Section 13-04, for removal details.
2. Use the Ford Rotunda key code cutting package (Tool 127-000003) to measure the depth of cut on the number six tumbler station of the original key.
^ Use this measurement to determine the correct service ignition lock set, Figure 2.
^ Refer to the following Ignition Lock Set Application Chart Figure 3, For correct parts usage.
3. Using the old ignition key, decode tumbler cut numbers 5, 7, 8, 9 and 10 using the called out tool.
4. Cut the new key position numbers 5, 7, 8, 9 and 10 using the called out tool.
5. Check the new key operation in the new ignition lock cylinder and the doors (both keys).
6. Install the new ignition lock cylinder in the steering column. Refer to the appropriate Car Service Manual for service details.
7. Start the vehicle to verify proper operation.
NOTE:
MAKE SURE THAT BOTH NEW KEYS WILL RETURN TO THE RUN POSITION FROM THE START POSITION WITHOUT DRAG. FOR FUTURE KEY CODE IDENTIFICATION, RETAIN BOTH OLD AND NEW KEY TAGS.
GREASING PROCEDURE - (VEHICLES BUILT BEFORE 11-1-90)
1. Remove the shift lever rubber cover from the lower slot on the lock cylinder housing and move it out of the way (column shift only).
2. Install the key lock cylinder and rotate it to the ACCESSORY position.
3. Cover the driver's seat carpet under the steering column and instrument panel with plastic or paper covering.
CAUTION:
USE CARE IN APPLYING GREASE AS IT IS UNDER PRESSURE AND WILL TEND TO MIGRATE OVER A LARGE AREA. LIGHTLY APPLY FINGER PRESSURE TO SPRAY BUTTON.
4. Using grease (FOAZ-19584-A), spray a liberal amount of grease into slots on the lock cylinder housing as shown in Figure 4.
NOTE:
IN ADDITION, FOR VEHICLES BUILT BEFORE NOVEMBER OF 1990, THE LOCK CYLINDER HOUSING MUST BE SPRAYED WITH THE RELEASED GREASE (FOAZ-19584-A). UNDER NO CIRCUMSTANCE SHOULD A SUBSTITUTE LUBRICANT BE USED.
5. Cycle the lock cylinder a number of times to ensure that the grease works its way into the upper actuator area. Regrease if necessary.
6. Wipe off excessive grease from the lock cylinder housing.
7. Remove the ignition lock cylinder from the housing and observe if grease has flowed into this area after performing Step 4. If housing is dry, spray grease in this area, Figure 5.
8. Reassemble the ignition lock assembly.
SUPERSEDES: 93-1-9
WARRANTY STATUS:
Eligible Under Bumper To Bumper Warranty Coverage For 1991 And Later Model Lincolns. Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage For Other Models
OPERATION DESCRIPTION TIME
930309A Replace Lock Cylinder And 0.8 Hr.
Ignition Switch
930309B Replace Lock Cylinder, 1.2 Hr.
Ignition Switch And
Lubricate Lock Cylinder
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 08
OASIS CODES: 112000, 205000