How do you remove the ignition lock cylinder - 1993 Plymouth Sundance

Ignition and Start Switch Replacement
Removal Procedure
Disconnect the battery ground cable. .
Remove the steering column filler panel.
Remove the knee bolster bracket.
Remove the instrument panel (I/P) cluster trim panel.
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 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.

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.

Ignition Lock Cylinder 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. Fig. 1: 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:
   
4. 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.
5. Rotate the lock cylinder using the lock cylinder key, to ensure correct mechanical operation in all positions.
6. 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. 1986-90 VEHICLES

1. Disconnect the negative battery cable.
2. Remove the steering wheel. For details, please refer to the procedure located earlier in this section.
3. Remove the two trim shroud halves after removing the three attaching screws.
4. Disengage the electrical connector from the key warning switch.
5. Using a 1?8 in. (3mm) diameter drill, carefully drill out the retaining pin, being careful not to drill deeper than 1?2 in. (13mm).
6. Place a suitable chisel at the base of the ignition lock cylinder cap, then, using a suitable hammer, strike the chisel with sharp blows to break the cap away from the lock cylinder.
7. Using a 3?8 in. (10mm) diameter drill, carefully drill down the middle of the ignition key slot approximately 1 3?4 in. (44mm) until the lock cylinder breaks loose from its breakaway base. Remove the lock cylinder and drill shavings from the lock cylinder housing.
8. Remove the retainer, washer, ignition switch and actuator. Thoroughly clean all the drill shavings from the casting.
9. Inspect the lock cylinder housing for damage from the removal operation. To install:
   
10. Replace the lock cylinder housing if it was damaged.
11. Install the actuator and ignition switch.
12. Install the trim and electrical parts.
13. Install a new ignition lock cylinder.
14. Install the steering wheel. For details, please refer to the procedure located earlier in this section.
15. Connect the negative battery cable.
16. Check the lock cylinder operation.

1991-95 VEHICLES

1. Disconnect the negative battery cable.
2. Remove the steering wheel.
3. Using locking pliers, twist the cylinder cap until it separates from the lock cylinder.
4. Using a 3?8 in. (10mm) diameter drill bit, drill down the middle of the ignition lock key slot approximately 1 3?4 in. (44mm) until the lock cylinder releases from its breakaway base. Remove the lock cylinder and drill shavings from the lock cylinder housing.
5. Remove the retainer, washer, ignition switch and actuator. Thoroughly clean all drill shavings and other foreign materials from the casting.
6. Inspect the lock cylinder housing for damage from the removal operation. If the housing is damaged, it must be replaced. To install:
   
7. Replace the lock cylinder housing, if damaged.
8. Install the actuator and ignition switch.
9. Install the trim and electrical parts.
10. Install the ignition lock cylinder.
11. Install the steering wheel.
12. Connect the negative battery cable, then check the lock cylinder operation.

Ignition Switch Removal & Installation To Remove:

1. Remove the steering column trim covers.
2. Remove the wire harness from the retainers as needed.
3. Slide the 2 connectors of the multifunction switch assembly out from the bulk head connector.
4. Detach the key alarm connector from the lock assembly.
5. Remove the ignition switch mounting screws and the ignition switch from the steering column.

Ignition switch removal/installation

To Install:

1. Install the ignition switch on the lock module.
   • Tighten the screws to 42 lb in (4.7 Nm).
2. Install the key alarm connector on the lock module.
3. Slide the turn signal and multifunction switch connectors into the bulkhead connector.
4. Install the harness in the original retainers.
5. Install the steering column trim covers.

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Ignition Lock Cylinder Removal & Installation To Remove:

1. Disconnect the negative cable from the battery.
2. Disable the supplemental inflatable restraint (SIR) system.
3. Remove the steering column trim covers.
4. Turn the ignition lock cylinder to the run position.
5. Using an awl with a bent tip, insert the tip into the access hole of the ignition lock cylinder.
6. Turn the lock cylinder to start and push down and hold the lock cylinder retaining pin.
7. Release the lock cylinder to the run position and withdraw the cylinder from the steering column.

Ignition lock cylinder removal

To Install:

1. Align the slot in the steering column to the tab on the lock cylinder and install the lock cylinder until it locks in place.
2. Install the steering column trim covers
3. Connect the negative cable to the battery
4. Check for correct operation

Ignition Lock Cylinder - Removal & Installation CAUTION The Supplemental Inflatable Restraint (SIR) system must be disarmed before working around the air bag or SIR wiring. Failure to do so may cause accidental deployment of the air bag, resulting in unnecessary SIR system repairs and/or personal injury.

1. Disconnect and isolate the negative battery cable from the battery.
2. In order to disarm the air bag system, allow the SIR system capacitor to discharge for at least 2 minutes, before performing any removal procedures.
3. Remove the screws that secure the parking brake release handle to the instrument panel.
4. Remove the screws that secure the bottom of the lower steering column cover to the instrument panel.
5. Disengage the retaining clip that holds the right side of the lower steering column cover to the instrument panel.
6. Remove the lower steering column cover from the vehicle.
7. Remove the mounting screws that hold the upper and lower steering column shrouds and remove the lower steering column shroud.
8. Install the ignition key and turn the key cylinder to the RUN position. This is important because it will not only aid in removal of the ignition lock, but will also place the socket (in the lock cylinder housing) in proper alignment for the installation of the replacement ignition lock.
9. Press in the lock cylinder retaining tab and remove the key cylinder (ignition lock).
   
   
   Fig. Depress the retaining tab to remove the key cylinder
   

To install:

1. Install the ignition key into the replacement ignition lock key cylinder. Turn the key to the RUN position. Depress the ignition lock key cylinder retaining tab.
2. Align the shaft at the end of the ignition lock cylinder with the socket in the end of the ignition lock cylinder housing.
3. Align the ignition lock cylinder with the grooves in the lock cylinder housing. Push the ignition lock cylinder into the housing until the retaining tab sticks through the opening in the lock cylinder housing.
4. Turn the ignition key to the OFF position and remove the key.
5. Install the lower steering column shroud and install the mounting screws.
6. Place the lower steering column cover into correct position on the lower instrument panel and engage the clip that secures the right side of the cover to the instrument panel.
7. Install the lower steering column mounting screws.
8. Install the mounting screws that hold the parking brake release handle to the instrument panel.
9. Reconnect the negative battery cable.

Hope helps (remember rated and comment this).

the actuator inside the sterring column that the lock cylinder turns is boken, this is a very complex job and is not for the home tech without a factory service manual.

Ignition Switch REMOVAL & INSTALLATION The ignition switch is located at the bottom of the ignition key cylinder body. To remove the ignition switch, first remove the ignition lock cylinder.

1993–99 Golf and Jetta

1. Disconnect the negative battery cable.
2. Center the steering wheel.
3. Remove the air bag.
4. Remove the steering column switches.
5. If the vehicle is equipped with an automatic transmission, detach the shift lock cable from the lock cylinder housing.
6. Remove the adapter sleeve from the steering column.
7. Remove the spring and horn contact ring from the steering column assembly.
8. Detach the sheer bolt.
9. Insert the ignition key and unlock the cylinder, then detach the wiring connectors.
10. Once all wiring has been detached, slide the housing off the steering column.
11. Mark and drill the lock cylinder as shown and described in the above procedure.
12. Compress the stop spring and pull the lock cylinder out of the steering column housing.
13. Put the new lock cylinder into the steering lock housing.
14. Insert the key into the lock cylinder.
15. While you gently turn the key, insert the lock cylinder fully into the housing.
16. The rest of the installation procedure is the reverse of removal. NOTE: Always use a new shear pin when installing the lock cylinder.
    

lock cylinder removal

Section 11-04: Steering Column 1996 Escort, Tracer Workshop Manual
REMOVAL AND INSTALLATION Ignition Switch Lock Cylinder Removal

1. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR DRIVER SIDE AIR BAG MODULE DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY GROUND CABLE MUST BE DISCONNECTED PRIOR TO SERVICING OR REPLACING ANY DRIVER SIDE AIR BAG MODULE SYSTEM COMPONENTS.
   Remove the steering wheel (3600). Refer to the procedure in this section.
   

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

1. Disconnect the ignition switch electrical connector.
   

1. Remove the ignition/shifter interlock cable mounting bracket bolt and position the ignition/shifter interlock cable mounting bracket and the ignition/shifter interlock cable (3F719) aside.
   
   
   
   
   

1. Remove the four steering column upper mounting bracket bolts and lower the steering column (3C529).
   

1. Use a hammer and chisel to make a groove in the head of each of the two ignition switch lock cylinder bracket bolts.
   
   
   
   
   

1. Remove the two ignition switch lock cylinder bracket bolts with a screwdriver and discard the bolts.
   
   
   
   
   

1. Remove the ignition switch lock cylinder and the ignition switch lock cylinder bracket.
   

Installation

1. Position the ignition switch lock cylinder and bracket and install two new bolts, tightening them only enough to hold the ignition switch lock cylinder in position.
   

1. With the key in the ignition, verify the operation of the ignition switch lock cylinder. If necessary, reposition the ignition switch lock cylinder until it operates properly.
   

1. Tighten the ignition switch lock cylinder bracket bolts until the bolt heads break off.
   

1. Position the steering column and install the four steering column upper mounting bracket bolts. Tighten the steering column upper mounting bracket bolts to 9-14 Nm (80-124 lb-in).
   

1. On vehicles equipped with tilt column, remove the upper mounting bracket retaining pin.
   

1. Position the ignition/shifter interlock cable mounting bracket and install the bolt. Tighten the ignition/shifter interlock cable mounting bracket bolt to 4-6 Nm (35-53 lb-in).
   

1. Connect the ignition switch electrical connector.
   

1. Install the multi-function switch. Refer to Section 11-05 for the installation procedure.
   

1. Install the steering wheel. Refer to the procedure in this section.
   

1. Inspect the shift interlock system. Refer to Section 07-05 for the procedure.
   

Lock Cylinder Functional
Removal

1. NOTE: The following procedure applies to vehicles that have functional ignition switch lock cylinders (11582), lock cylinder keys are available for these vehicles or the lock cylinder key numbers are known and the proper key can be made.
   
   Disconnect battery ground cable (14301). Refer to Section 14-01 .
   

1. Turn ignition switch lock cylinder to RUN position.
   

1. Place a 3.17 mm (1/8-inch) diameter wire pin or small drift punch in hole in lower steering column shroud (3530) under ignition switch (11572). Press retaining pin while pulling out on ignition switch lock cylinder to remove it from steering column lock cylinder housing (3511).
   

Installation

1. Install ignition switch lock cylinder by turning it to RUN position. Insert ignition switch lock cylinder into steering column lock cylinder housing. Make sure ignition switch lock cylinder is fully seated and aligned in interlocking washer before turning ignition switch lock cylinder to OFF position. This will permit cylinder retaining pin to extend into steering column tube flange hole.
   

1. Rotate ignition switch lock cylinder, using lock cylinder key, to ensure correct mechanical operation in all positions.
   

1. Connect battery ground cable.