Removing Faulty Ignition Switch - It's STUCK - Defender Source
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  #1  
Old July 27th, 2010, 12:02 PM
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Removing Faulty Ignition Switch - It's STUCK

My ignition switch fell apart into multiple pieces inside my dash. It looks like the glue inside failed when the temperatures hit 105+ degrees a few weeks ago. The only piece still left inside the key/steering-lock cylinder is the metal base to the ignition switch. I have tried everything: small needle nose pliers, a long flat head screw driver, etc. It just seems confusingly STUCK in there.

I have already replaced the ignition switch with a new one, and reconnected all of the ignition switch wires to the new piece. I can start and drive the car by undoing the steering lock with the key in the ignition, and turning over the new ignition switch with a flat head screw driver to turn it on. I have to wear pastel-colored shirts so that people don't think I'm stealing the car.

I have removed the small screw that secures the ignition switch to the key/steering-lock cylinder, so it is not that.

pics of the new ignition switch vs. what I saw when I took out the dash to replace:

http://www.defendersource.com/forum/...2&postcount=22

-------------------
Pic 1) A picture of what I saw when I unscrewed the dash. This is the ignition switch plug that failed.
Pic 2) A picture of what was left of the base of the ignition switch. All of the plastic you see has since fallen out of there, so all I am left with is the stuck metal base of the ignition switch.

COULD HAVE BEEN SUCH AN EASY FIX.
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  #2  
Old July 27th, 2010, 12:11 PM
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Josh,

Can't really see with the pics but have you tried pb blaster or heating the outside of the metal base to expand it?
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  #3  
Old July 27th, 2010, 12:22 PM
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And before some smart-ass asks...NO, it is not Rhino-lined in there.

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  #4  
Old July 27th, 2010, 12:29 PM
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There are 2 little screws.
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  #5  
Old July 27th, 2010, 12:30 PM
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removal diagram only shows one. Any chance you could tell me where the elusive #2 is?

------ Follow up post added July 27th, 2010 12:31 PM ------

----

Same horizontal just on the other side (just to make it that much more difficult)?
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  #6  
Old July 27th, 2010, 12:35 PM
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Quote:
Originally Posted by rijosho View Post
removal diagram only shows one. Any chance you could tell me where the elusive #2 is?

------ Follow up post added July 27th, 2010 12:31 PM ------

----

Same horizontal just on the other side (just to make it that much more difficult)?
Yup, 180 from the one you can see.
I never try to do those in the car. I drill the safety bolts and remove the entire column lock assmebly. In the long run it takes way less time than dicking around in the tight space behind the dash.

Don't let the little silver key-way thingy on the end of the ignition lock fall down in the dash, and don't forget to put it back in (it goes in the place where you are using the screwdriver now).
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  #7  
Old July 27th, 2010, 01:19 PM
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Thanks again, Mike.

Yeah, this would have been much simpler had I just been able to get the shear bolts around the steering column out with a punch or stud extractor (or drilled them out) and worked on this out in the open. Hopefully I won't have to be back in here any time soon.

Do you always replace them with shear bolts again for anti-theft? Everything in there is built for anti-theft, but it's pretty funny how easy it was to get the truck going with a phillips head and a flat head screw driver.
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Old July 27th, 2010, 02:00 PM
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Quote:
Originally Posted by rijosho View Post
Thanks again, Mike.

Yeah, this would have been much simpler had I just been able to get the shear bolts around the steering column out with a punch or stud extractor (or drilled them out) and worked on this out in the open. Hopefully I won't have to be back in here any time soon.

Do you always replace them with shear bolts again for anti-theft? Everything in there is built for anti-theft, but it's pretty funny how easy it was to get the truck going with a phillips head and a flat head screw driver.
I can't do it on customer cars, but if you want a "short-cut" use a cut off wheel and cut slots in the safety bolt heads. then you can use a screwdriver to remove them, and put them back.

On customer cars we do use the correct safety bolts.
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  #9  
Old July 27th, 2010, 08:53 PM
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If you can't get power to the truck to use a dremel a small hacksaw could probably be used to slot the head.
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  #10  
Old July 28th, 2010, 10:19 AM
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x2 dremel or hacksaw the heads of the shear bolts, makes it SO easy. I actually changed the ignition in mine using a power converter and dremel on the side of the road one day.
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  #11  
Old March 8th, 2016, 12:22 PM
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yay- I finally got to try my hand at this job.
I did the Dremel method...cut some slots in the heads of the shear bolts to fit a flat screwdriver.
The hacksaw method renders the bolts unusable.


.
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Old March 8th, 2016, 12:31 PM
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Says the dentist...

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Originally Posted by Nomar View Post
I did the Dremel method...


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Old March 8th, 2016, 12:53 PM
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Originally Posted by Ren Ching View Post
Says the dentist...
and that is actually a dental drill; I used a 556 Straight Fissure Crosscut

Straight Fissure Crosscut 556 Friction Grip Midwest Bur - FG Burs - Burs and Diamonds - Supplies

makes a nice cut


.
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Old March 8th, 2016, 03:11 PM
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Quote:
Originally Posted by Nomar View Post
and that is actually a dental drill; I used a 556 Straight Fissure Crosscut

Straight Fissure Crosscut 556 Friction Grip Midwest Bur - FG Burs - Burs and Diamonds - Supplies

makes a nice cut


.

I should get some of those from my parents! I already have an assortment of dental picks and mirrors.
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Old March 8th, 2016, 03:29 PM
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Old March 8th, 2016, 03:46 PM
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Originally Posted by nathanwind View Post
Go push-button start and never look back!
hey now-- I thought about that, too

link that write-up here again


.
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  #17  
Old March 8th, 2016, 03:48 PM
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hey now-- I thought about that, too

link that write-up here again


.
Well, I've sort of been "emailing" it for reasons not to publish how to hotwire a Defender . I'll shoot it over to you...
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Old March 8th, 2016, 04:13 PM
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Well, I've sort of been "emailing" it for reasons not to publish how to hotwire a Defender . I'll shoot it over to you...
good point!


.
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  #19  
Old March 9th, 2016, 05:22 AM
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good point! .
I've always thought it would be sorta cool to wire the push start to the Cig Lighter.
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  #20  
Old April 9th, 2016, 01:35 AM
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Well, I've sort of been "emailing" it for reasons not to publish how to hotwire a Defender . I'll shoot it over to you...
I've had the same problem with my ignition and would love to setup a push button start. Can you shoot me an email with instructions please! Thanks,
Michael
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