Ignition Barrel/Tumbler query

[Fabi05]

Hi all

I cant seem to find the answer to this online anywhere - A small spring inside my ignition barrel broke in 2 and wont let the key click past II.

Inside the tumbler is a small semi-circle and a square with a little semi-circle on top of it - I've added a picture below. Are they all the same fitting? The end of my key mechanism fits into this, so would it be possible to buy a new ignition barrel and fit my current key into this?

I am attempting to ideally keep my current key as it would cost a lot more and be a lot more work to replace all the parts to have a working key/fob set on the car.

[Baffler]

Not sure if the pictures are still visible but is this thread of any use? Ignition won't turn beyond position II

[Fabi05]

Originally Posted by Baffler

Not sure if the pictures are still visible but is this thread of any use? Ignition won't turn beyond position II

Hi, yes this was very informative and reassuring, I saw this thread previously but failed to see the multiple pages it had! I have the same issue with the small metal snapped in half, and spent a good hour trying to fish them out but it seemed impossible with the metal plunger that you can see still in the ignition barrel in my picture. I noticed you were able to remove yours in your thread?

I'm currently looking into buying a.. quite pricey... ignition barrel from a breaker yard and was hoping I'd be able to remove mine, replace it with that one and hopefully pop my key mechanism into that one as the fitting all looks the same across every x40 p2 i've seen so far? Would rather not have to disassemble the current ignition barrel in my car though.. with all the shear bolts and whatnot.

Would you be able to clarify how you managed to remove the metal plunger from the barrel where the key mechanism fits in? That way I'd hopefully be able to just replace that tiny half-moon metal piece!

[Baffler]

Originally Posted by Fabi05

Would you be able to clarify how you managed to remove the metal plunger from the barrel where the key mechanism fits in? That way I'd hopefully be able to just replace that tiny half-moon metal piece!

I'm afraid many moons have passed since removal so I can't remember the intricacies of the mechanism. I do remember my anticipation of removing that inner portion, seen in your pic, for fear the broken pieces dropping into the locking mechanism...hence why I removed the whole assembly.

Are you able to view the pictures with that inner portion removed?

[Fabi05]

Originally Posted by Baffler

Are you able to view the pictures with that inner portion removed?

Yeah I've seen these, I'm currently on that step of trying to figure out how to remove that. I couldnt get mine out - but I havent been able to pull it properly as I dont have any needle pliers.

I'm likely going to purchase the same ignition barrel and mess around with the working one out of the car before doing anything with the one in my car as the other day I immobilised my car as I couldnt get the key mechanism back in as the inner portion was locked up by the broken little metal pieces, and without the key I couldnt turn off the steering lock!

Will probably give it a go once I get the new one. Just not looking forwards to having to deal with the shear bolts

[Baffler]

Originally Posted by Fabi05

Yeah I've seen these, I'm currently on that step of trying to figure out how to remove that. I couldnt get mine out - but I havent been able to pull it properly as I dont have any needle pliers.

I was going to say try pull it out with some needle pliers and then attach a length of suitable rubber hose to your vacuum cleaner and try fish out any offending broken bits. By far the easiest and quickest option. Unfortunately, I think they are non-ferrous metal so a telescopic magnet is not much use but, by all means, correct me on that.

Originally Posted by Fabi05

I'm likely going to purchase the same ignition barrel and mess around with the working one out of the car before doing anything with the one in my car as the other day I immobilised my car as I couldnt get the key mechanism back in as the inner portion was locked up by the broken little metal pieces, and without the key I couldnt turn off the steering lock!

I would hate to see you going to any unnecessary expense, I didn't, and just remove the broken bits and reassemble. Gatos was so very kind to send me the actual gubbins but they have sat in a drawer ever since.

Originally Posted by Fabi05

Will probably give it a go once I get the new one. Just not looking forwards to having to deal with the shear bolts

Some aspects of their removal is coming back to me now. It's not the easiest of positions to work comfortably in so, if you must remove the whole assembly, beg/borrow/steal a Dremmel and cut slots into the heads of the shear screws. They're not overly tight so any initial purchase you can make on them they should simply walk out.

[Fabi05]

Originally Posted by Baffler

I was going to say try pull it out with some needle pliers and then attach a length of suitable rubber hose to your vacuum cleaner and try fish out any offending broken bits. By far the easiest and quickest option. Unfortunately, I think they are non-ferrous metal so a telescopic magnet is not much use but, by all means, correct me on that.



I would hate to see you going to any unnecessary expense, I didn't, and just remove the broken bits and reassemble. Gatos was so very kind to send me the actual gubbins but they have sat in a drawer ever since.

I think I recall reading on your thread but I can't seem to find it in there anymore - does the whole mechanism work without the small broken metal in there? As far as I'm aware the key does turn freely without the small metal pieces seizing up the whole thing but I'm struggling to piece together what that tiny half moon metal does?

If it works without it then I'll give buy some needle nosed pliers and give it a crack at removing it tomorrow.. would save me a lot of money as I was planning on buying the used one just for that really tiny piece of metal from it..
--

Edit: I found the pic in the thread where you showed the broken pieces and mentioned it all still worked without them - These are the same (from what I can see) broken pieces in mine so I'll give it a shot tomorrow and see if I can remove them.

I've currently got the starter switch angled slightly below what it originally was so that the key can start the car but I'd prefer having a better solution than drilling a new hole into the steering column and fixing the actual issue or bettering it.

[Baffler]

Originally Posted by Fabi05

I think I recall reading on your thread but I can't seem to find it in there anymore - does the whole mechanism work without the small broken metal in there? As far as I'm aware the key does turn freely without the small metal pieces seizing up the whole thing but I'm struggling to piece together what that tiny half moon metal does?

If it works without it then I'll give buy some needle nosed pliers and give it a crack at removing it tomorrow.. would save me a lot of money as I was planning on buying the used one just for that really tiny piece of metal from it..

I'm still struggling to understand its function. I just completely removed it, it wasn't present on my Phase1 '98 S40 assembly, so replaced without said gubbins and it worked absolutely fine up to point of sale in 2017. Never had an issue in that time.

[Fabi05]

Just an update:

I have bought some pliers and pulled out the inner portion of the ignition barrel, came out just fine and the small tiny steering lock cam piece (image below) was stuck in but with a bit of convincing it came right out.

There was a spring at the bottom of the steering lock that supposedly connects to this cam piece but I couldnt get it out and ended up just leaving it in. Oddly enough the metal piece doesn't look broken or sheared off anywhere? I couldn't find any other loose or broken looking pieces inside the ignition so I took this out - put everything back together and the key works and clicks fully as it used to with the starter switch and all in at its original angle.

Tested the steering lock and although it seems to travel much further than it used to (Almost a full rotation) - it also works and locks the wheel in place.

From my 2 minutes of testing the key and steering lock with it all back together - all looks fine and working.

Thanks Liam for your help it's saved me a load of frustration, time and money!!

[Baffler]

That is wonderful news, Fabi05, and thanks for keeping us updated. So glad you didn't need to endure the removal of the shear screws.

Happy days!