Ignition Switch - Mechanical

The following conditions can cause difficulty in operating the ignition switch and lock cylinder:

• Burrs on the lock cylinder key
• Insufficient lube on the lock cylinder
• Binding lock cylinder
• Burrs or foreign material around the rack and pinion actuator in the lock cylinder housing
• Insufficient lube on the actuator (do not apply lubricant to the inside of the ignition switch.)
• Binding ignition switch

If the steering wheel lock is engaged with the wheels loaded against a curb, high effort is necessary to turn the key from lock. Turn the steering wheel to either side of the lock to unload the system.

Perform the following test to determine if the ignition switch and lock cylinder are operating correctly.

1. Inspect the ignition key for any burrs, damage or incorrect cut. Replace the ignition key as necessary.
2. NOTE: The steering wheel may be locked full left or full right. If the steering wheel is locked, it is necessary to apply turning effort to the steering wheel in the direction of the lock while turning the key.

   Turn the key to the ACC position and then the RUN position.

   • If the ignition key turns to the ACC and RUN position, continue with Step 3.
   • If the ignition key will not turn to the ACC and RUN position, continue with Step  4.
3. NOTE: The ignition switch and lock cylinder should return from the START position back to the RUN position without assistance.

   Turn the ignition key to the START position and release the key.

   • If the ignition switch and lock cylinder return from the START position back to the RUN position without assistance, the ignition switch is operating correctly at this time.
   • If the ignition switch and lock cylinder do not return from the START position back to the RUN position without assistance, continue with Step 4.
4. Remove the ignition lock cylinder. Refer to HANDLES, LOCKS, LATCHES AND ENTRY SYSTEMS .
5. Rotate the ignition lock cylinder through all of the switch positions.
   • If the lock cylinder operates correctly, continue with Step 6.
   • If the lock cylinder does not operate correctly, install a new ignition lock cylinder. Refer to HANDLES, LOCKS, LATCHES AND ENTRY SYSTEMS .
6. Check for binding or sticking ignition switch actuating rod, burrs around the rack-and-pinion actuator in the ignition lock cylinder housing or insufficient lubrication.
   • If there is sufficient lubrication and there are no burrs, binding or sticking conditions, install a new ignition switch. Refer to Ignition Switch .
   • If there is insufficient lubrication, burrs, binding or sticking conditions, repair or lubricate as necessary.