Ignition Switch: Service and Repair

1. Disconnect battery ground cable.
2. Disconnect wiring harness connector to driver's seat heating element, if equipped, and remove seat.
3. Place automatic transmission in park or manual transmission in reverse and remove ignition key.
4. On automatic transmission models, remove shift indicator plate and top cover after disconnecting indicator lamp; on manual transmission models, remove shifter boot and top cover.
5. Pull carpet away from shifter cover.
6. Remove center rear console as follows:
a. Move seats to rear and apply handbrake.
b. Remove rear ashtray and 5 console retaining screws.
c. Disconnect wiring harness connectors and remove console, then remove heater duct.
7. If lock cylinder is to be replaced on manual transmission models, remove tapered pin from joint between gear lever and selector rod, and disconnect selector rod.
8. Disconnect wiring harness connectors to ignition switch, noting position for reassembly.
9. Disconnect wiring harness connectors to back-up lamp and neutral safety switches, if equipped.
10. Remove bolts securing gear lever housing using tool 891237 on all except Model 900 with manual transmission. On 900 manual transmission models, use tool 8790370.

Fig. 2 Ignition & starter switch contact alignment:

11. Replace ignition switch as follows:
a. Raise housing slightly, twist to expose cover plate screws, and remove plate.
b. Remove ignition switch retaining screws and switch.
c. Rotate switch to align mark (2) with arrow (3), Fig. 2.
d. Ensure that key is in lock (L) position and install switch with locating stud (1), Fig. 2, in slot on gear lever housing.

Fig. 3 Ignition lock cylinder removal with key:

12. Replace lock cylinder with key as follows:
a. On automatic transmission models, loosen bottom cover screws, remove cable bracket clip, and remove gear lever housing.
b. On manual transmission models, remove gear lever housing assembly.
c. Turn ignition key half way between Lock (L) and garage (G) positions.
d. Depress lock cylinder retaining pin, Fig. 3, with a suitable pick, and pull cylinder from housing.
e. Install lock with key turned as in step c, ensuring that cylinder is aligned with drive gear.

Fig. 4 Ignition lock cylinder removal with key missing:

13. Replace lock cylinder with key missing as follows:
a. Drill out plug covering hole for lock cylinder retaining pin on LH side of gear lever housing.
b. Using a suitable punch, drive lock retaining pin in approximately .008 inch, Fig. 4, and remove lock cylinder. Lock cylinder must be replaced after forcing retaining pin.
c. Install new lock cylinder as in step 13.
14. Reverse procedure to install components and adjust transmission linkage as needed.