Ignition Lock: Service and Repair

Fig. 7 Ignition Lock Replacement Preparation:

Before commencing any work, Service Precautions
Refer to Steering Columns for illustrations for the following procedure. Obtain new shear head bolt before starting procedure. Obtain audio coded anti-theft code, then disconnect battery ground cable.
1. Obtain audio coded anti-theft code, then disconnect battery ground cable.
2. Remove steering column as outlined under "Steering Columns.
3. Place steering column in a suitable vice as shown in Fig. 7 Ensure U-joint is supported on face of vice so steering shaft will not move down in column.
4. Remove spacer or spring and locking washer, as equipped, from steering shaft using suitable tools.
5. On models with shifter lock cable, disconnect shifter lock cable from ignition lock.
6. Using a suitable chisel and hammer, back out end of shear head bolt retaining ignition lock to steering column on lefthand side. Alternatively, use a suitable drill motor to drill out shear head bolt retaining ignition lock to steering column on lefthand side.
7. Ensure body of shear head bolt is either drilled out or backed out sufficiently to clear mounting tab of steering column during lock removal.
8. Unlock steering lock from column with ignition key prior to removing ignition lock.
9. Slide ignition lock, with upper trim if necessary, off steering column. Heat lock body with hot air blower if necessary.
10. If unable to unlock ignition lock, remove complete steering column if necessary, as outlined under "Steering Columns, then remove key tumbler as outlined below.

Fig. 8 Ignition Lock Cylinder Drilling Dimensions:

11. If key tumbler removal or replacement is required, proceed as follows:
a. Insert ignition key into ignition lock cylinder.
b. Using 1/8 inch drill bit, drill hole in lock housing approximately 1/8 inch deep as shown in Fig. 8 Dimension A = 0.47 inch, dimension B = .39 inch.
c. Using a suitable drift punch, remove lock cylinder with key by pressing in check spring using hole previously drilled.
d. When installing lock tumbler, ensure tumbler and lock assembly are in OFF position.

Fig. 9 Ignition Lock To Column Position:

Fig. 10 Steering Shaft Tension Spring Positioning:

12. Reverse procedure to install, noting the following:
a. On Eurovan models, position ignition lock as shown in Fig. 9 Dimension A = 3.7 inches. Tighten shear bolt until head breaks off.
b. Position locking washer and spring as shown in Fig. 10 Dimension A = 2.5 inches.
f. On models with shifter lock cable, adjust shifter lock cable as outlined under "Automatic Transmissions/Transaxles".
g. Reverse remaining procedures to install. Reset audio coded anti-theft system.