How to change the lock cylinder

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This is not an easy repair due to anit theft requirements. need to chisel off bolts.

Section 11-04: Steering Column 1997 Probe Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 05/17/2000
Ignition Switch Lock Cylinder Removal

1. Remove the steering wheel (3600). Refer to the procedure in this section.
   

1. Remove the four lower steering column shroud screws.
   
   
   
   
   

1. Separate the upper and lower steering column shrouds.
   

1. Remove the ignition switch lock cylinder illumination miniature bulb from the lower steering column shroud.
   

1. Remove the upper and lower steering column shrouds.
   

1. Remove the multi-function switch (13K359). Refer to Section 11-05 for the removal and installation procedure.
   

1. If equipped, remove the ignition/shifter interlock cable screw.
   

1. Disconnect the ignition/shifter interlock cable (3F719) from ignition switch lock cylinder (11582).
   

1. Use a chisel to remove the two ignition switch lock cylinder bolts.
   

1. Remove the ignition switch lock cylinder from the steering column.
   

1. Disconnect the ignition key reminder switch electrical connector.
   

1. If necessary, remove the ignition key reminder switch.
   
   
   
   
   

Installation
NOTE: Use new ignition switch lock cylinder bolts. Tighten the bolts until the bolt heads break off. Check for proper ignition switch (11572) operation.

To install, reverse the removal procedure.

Here's a copy of a service bulletin on your problem.

I'll bet the dealer says $300 for parts and 2 hrs labor.:screwy:

Ignition Key - Will Not Turn And/Or Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT:
Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS:
1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW:
This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED:
Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or
IL-ECM-100
T-27 Torx Bit
T-25 Torx Bit
T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key.
NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180°and reinsert the key into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180°and reinsert the key into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT.
STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE.
WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180°and reinsert the key into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).

disconnect the battery and pull the air bag fuse out to diable the air bag. Remove the steering coulmb trim covers and expose the lock cylinder. If the lock cylinder can be turned and is functional then push in the bottom tab and turn the lock cylinder then pull the whole cylinder out. If the keys broke inside and the lock cylinder is not functional the bottom tab will need to be drilled out.

If your key is worn try getting a new one cut.
The ignition lock cylinder and keys do not contain any coded electronic components. The lock cylinder housing contains the coded electronic components. Changing an ignition lock cylinder or replacing a key is a purely mechanical process which does not affect the vehicle theft deterrent system. To replace an existing key, simply cut a new key to match the existing one. If no keys are available, the lock cylinder must be changed. To change the lock cylinder, simply replace the existing lock cylinder with one of the same type.
If you are unable to operate the ignition cylinder with a new key then you will probably need to replace the cylinder and switch.Replacement of the switch involves reprogramming
The system may be programmed with or without a scan tool.
There is a way to get the cylinder out without replacing the switch but this procedure should be performed by a qualified GM technician as it involves removal of the switch and some precise drilling.

Below are instructions for changing the lock cylinder as well as a few diagrams. Best of luck.
Greg

1. Disconnect the negative battery cable.
2. Remove the lock cylinder bezel from the steering column shroud by carefully prying with a thin bladed screwdriver.
3. Remove the shroud fasteners and remove the steering column upper and lower shroud panels.
4. Insert the key into the ignition lock cylinder and rotate to the RUN position. Then rotate the ignition cylinder back to the ACC position.
5. Depress the locking button on the side of ignition module assembly with a thin pick-type tool. Slide the lock cylinder assembly from the ignition module.

INSTALLATION:

1. Insert the key into the ignition lock cylinder and install into the ignition module.
2. Install the steering column upper and lower shroud panels and the shroud fasteners.
3. Install the lock cylinder bezel.

Reconnect the negative battery cable.

REMOVAL

1. On models equipped with airbag, disarm airbag as described under MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING.
2. On all models, disconnect battery ground cable.
3. Remove ignition switch as described under STARTING AND CHARGING SYSTEMS/COMPONENT REPLACEMENT AND REPAIR PROCEDURES/IGNITION SWITCH.
4. Remove key light case from lock body, if equipped.
5. On 1989 Accord models, place ignition lock cylinder in the ACC position.
6. On except 1989 Accord, place ignition lock in the I position.
7. On all models, position suitable punch into hole on lock cylinder housing and depress pin, then remove lock cylinder from housing.

INSTALLATION

1. On 1989 Accord models, install ignition lock cylinder as follows:

1. Place ignition lock cylinder in the LOCK position.
2. Rotate key until it is almost at the ACC position, then insert lock cylinder until pin contacts housing.
3. Rotate key to ACC position, then push pin in and insert lock cylinder into housing until pin clicks into place.

1. On except 1989 Accord, install ignition lock cylinder as follows:

1. Place ignition lock cylinder in the O position.
2. Rotate key until it is almost at the I position, then insert lock cylinder until pin contacts housing.
3. Rotate key to I position, then push pin in and insert lock cylinder into housing until pin clicks into place.

1. Install ignition switch and connect battery ground cable.

SRS wire harness is routed near the ignition switch.

CAUTION:

• All SRS electrical wiring harnesses are covered with yellow outer insulation.
• Before disconnecting the SRS wire harness, install the short connector on the airbag.
• Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring.

IGNITION SWITCH

1. Remove the steering wheel, then remove the steering column covers.
2. Disconnect the 7-P connector from the under-dash fuse box.
3. Insert the key and turn it to "0."
4. Remove the 2 screws and replace the base of the switch.

Ignition Lock Cylinder
Ford Taurus/Sable 1986-1995 Repair Information





REMOVAL & INSTALLATION

Functional Lock


The following procedure applies to vehicles that have functional lock cylinders. Such cylinders either have a key available or known key numbers from which a key can be made.

1. Disconnect the negative battery cable.
   
2. Turn the lock cylinder key to the RUN position.
   
3. Using a 1/8 in. (3mm) diameter wire pin or a small drift, depress the lock cylinder retaining pin through the access hole in the upper steering column shroud (under the ignition lock cylinder) while pulling out on the lock cylinder. Remove the lock cylinder from the column.
   

Using the key, turn the ignition lock cylinder to the RUN position, then depress the retaining pin using a wire pin or small drift

To install:

1. Install the lock cylinder by turning it to the RUN position and depressing the retaining pin. Insert the lock cylinder into its housing. Make sure the cylinder is fully seated and aligned in the interlocking washer before turning the key to the OFF position. This will permit the cylinder retaining pin to extend into the cylinder housing.
   
2. Rotate the lock cylinder using the lock cylinder key, to ensure correct mechanical operation in all positions.
   
3. Connect the negative battery cable.
   

Non-Functional Lock
The following procedure applies to vehicles in which the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken key, unknown key number or a lock cylinder cap that has been damaged and/or broken to the extent that the lock cylinder cannot be rotated.

I have 07 Pontiac Grand Prix, the wrong key was inserted into the ignition the other day. Now when I try to use the correct key it will not insert completly in the ignition, goes in until last 1/4in of key. Im stuck, I bought the new lock cylinder but how do I get the old one out? I cant get the key to insert all the way so I cant get it to the "On" position, it will not turn at all. The key that was inserted in error is whole and nothing is missing it seems like there is something stuck. Any help would be appreciated...

Ignition and Start Switch Replacement
Removal Procedure
Disconnect the battery ground cable. Refer to Battery Negative Cable Disconnect and Connect Procedure in Engine Electrical.
Remove the steering column filler panel. Refer to Steering Column Filler Replacement .
Remove the knee bolster bracket. Refer to Bracket Replacement - Knee Bolster .
Remove the instrument panel (I/P) cluster trim panel. Refer to Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster .
Remove the ignition switch bolts.
Lower the ignition switch away from the instrument carrier.
Insert the key into the ignition lock cylinder. Turn the key to the ON/RUN position.
Depress the transaxle park/lock cable retainer to release. Pull to remove the park/lock cable from the ignition switch.
Important: The Passlock? electrical connector cannot be removed until the lock cylinder is removed.

Depress and hold the detent on the bottom of the ignition switch in order to release the ignition lock cylinder. Remove the ignition lock cylinder with the key.
Disconnect the Passlock? electrical connector.
Disconnect the electrical connectors.
Important: Ignition switch lock cylinder that won't rotate or is seized.

Perform the following procedure if the ignition switch lock cylinder is seized or won't rotate.
12.1. Protect the immediate work area with suitable material such as clean shop towels or a clean fender cover.

12.2. Locate the surface for the ignition switch lock cylinder release button (2) on the plastic ignition switch housing and center punch a location (1) on the "rib" approximately 3/8 inch reward (toward the key entry end) from the cylinder release button.

12.3. Carefully drill a pilot hole through the plastic housing with a 1/8 inch drill bit.

12.4. Carefully drill a larger hole at the pilot location, and slightly into the ignition switch lock cylinder surface to break the release button retaining spring using a 9/32 inch drill bit.

12.5. Remove portions of the broken spring from the hole using a small suitable tool.

12.6. Grasp the ignition switch lock cylinder and remove it from the switch housing.

12.7. Remove any plastic "flash" from the drilling operation, and using compressed air blow out the ignition switch assembly.

12.8. Follow service manual procedures when cylinder cording is required. Refer to Key and Lock Cylinder Coding in General Information.

Installation Procedure
If the lock cylinder would not rotate or was seized, perform the following procedure:
1.1. Install the new ignition switch lock cylinder as required by rotating both the cylinder and the ignition switch to the ON position.

1.2. Push the ignition switch lock cylinder into the ignition switch housing until fully seated.

1.3. You may have to slightly depress the release button as the button passes by the 9/32-in hole previously drilled in the ignition switch housing.
Connect the electrical connectors.
Connect the Passlock? electrical connector.
Connect the park/lock cable to the ignition switch Turn the key to the ON/RUN position. Install the ignition lock cylinder into the ignition switch. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger.
Remove the key
Position the ignition switch to the instrument carrier.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Install the ignition switch bolts.
Tighten

Tighten the bolts to 10 N?m (89 lb in).

Install the trim plate bezel to the I/P cluster. Refer to Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster .
Install the knee bolster bracket. Refer to Bracket Replacement - Knee Bolster .
Install the steering column filler panel. Refer to Steering Column Filler Replacement .
Connect the battery ground cable. Refer to Battery Negative Cable Disconnect and Connect Procedure in Engine Electrical.

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