Locks: Service and Repair

Key and Lock Cylinder Coding

Ignition Lock Cylinder





The ignition lock cylinder only uses 7 of the 10 cut positions, 2 through 8. The ignition cylinder tumblers (3) are located on alternate sides of the cylinder (1). They are snap-in and self-retaining. It follows the key code with the first tumbler being the first depth of the key code, closest to the head of the key.

Note: All lock cylinders for side milled keys have right and left tumblers. The location of the tooth of the tumbler determines whether it is right of left. Illustrations in this procedure show the right tumblers on the top and the left tumblers on the bottom. All tumblers are marked 1R, 1L, 2R, or 2L. The number being cut depth and the letter meaning right or left.

1. Hold the ignition cylinder assembly (1) so that the side with the tumbler spring pocket located closest to the head of the cylinder is facing up.
2. Insert the tumbler springs (2) into each of the 4 spring pockets of the cylinder assembly.
3. The first tumbler (3) to be loaded will be the second key cut position, the second number in the key code. Install the first tumbler in the slot over the spring. Install the remaining tumblers for cuts 2, 4, 6, and 8 following the key code and the same process. Pressing the tumblers in place until they are secure.
4. Rotate the cylinder assembly. Insert the tumbler spring into each of the spring pockets of the cylinder assembly.
5. The first tumbler (3) to be loaded will be the third key cut position, the third number in the key code. Install the first tumbler in the slot over the spring. Install the remaining tumblers for cuts 5, 7, and 9 following the key code and the same process. Pressing the tumblers in place until they are secure.
6. Inspect for correct loading of the tumblers by inserting the key into the cylinder. The side bar should drop flush with the lock cylinder body diameter.
7. Lightly lubricate the outside surfaces in the tumbler area of the lock body and down the key slot using the provided grease. Insert and extract the key 5 times to lubricate the keyway.
8. Line up the lock to the run position. Insert the lock in the steering column. Rotate the lock to key out position and remove the key. Insert the key and rotate the lock 3 times to distribute the grease from the lock to the column housing inside diameter.

Front Side Door Lock Cylinder





The front side door lock cylinder only uses 8 of the 10 cut positions, 3 through 10 (when counting from the key head). The tumbler orientations alternate in adjacent locations from side to side with four each side.

Note: The door lock cylinder tumblers (3) are not self-retaining and must be held in place if the key is not fully inserted into the lock cylinder or until the cylinder (1) is assembled into the case (4).

1. Hold the cylinder (1) positioned so that the side with the V-shaped groove is facing to the right.
2. Insert the tumbler springs (2) into the 4 tumbler spring wells.
3. The first tumbler to be loaded will be key cut position number 3 (the third number in the key code). Determine the cut depth at this position and install the corresponding tumbler (3) into the tumbler slot nearest the front of the lock cylinder assembly (the end where the key is inserted).
4. In the same manner, determine the cut depth and corresponding tumbler and install the three remaining tumblers (3) into the tumbler slots located at the key cut position 5, 7, and 9.
5. Check the correct loading by holding the tumblers (3) in position and fully inserting the key into the cylinder (1). All the tumblers should be flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so that the tumbler spring wells on the opposite side are facing upward and then remove the key. Remember the tumblers (3) are not self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the four tumbler spring wells.
8. The first tumbler to be loaded will be key cut position 4. Determine the cut depth at the position and install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder.
9. In the same manner, determine the cut depth and corresponding tumbler and install the three remaining tumblers (3) into tumbler slots located at the key cut positions 6, 8 and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching key into the cylinder (1). All tumblers should be flush with the outside diameter of the cylinder.
11. Lightly lubricate tumbler (3) surface using the lubrication provided.
12. With the key fully inserted into the cylinder, install the cylinder into the case (4).
13. Remove the key being careful to keep the coded cylinder (1) fully inserted into the case (4).
14. Insert one shutter spring (5) into the shutter spring hole located on the front face of the cylinder (1).
15. Insert one shutter return spring (6) into the spring pocket located on the front face of the cylinder (1).
16. Install the shutter (7) on top of the shutter return spring (6) and into the recessed grooves in the front face of the cylinder (1). Be sure that the hooked end of the shutter return spring is positioned underneath the shutter. The shutter will need to be held in place against the force of the shutter return spring until the shutter cover (8) is installed.
17. Install the shutter cover (8) onto the top of the cylinder (1). Be sure that the legs on the shutter cover snap onto the cylinder head and the ends of the shutter assembly (7) are positioned in the grooves located in the front face of the cylinder.
18. Install the lock cylinder cap (9) by aligning the drain slot in the cap with the bottom of the case (4). Snap the cap into place with light hand pressure. Be sure the cap is securely retained on the case. Also, be sure that the shutter spring (5) and shutter return spring (6) push the shutter (7) and shutter cover (8) up against the inside surface of the cap.
19. Install the lever (10) onto the end of the cylinder (1).
20. Install the retaining ring (11) in the groove at the end of the cylinder (1) to secure the lever (10) to the cylinder.
21. Snap the rod retainer (12) into the hole in the lever (10).
22. Mount the theft deterrent switch (13) onto the flange of the case (4) with the two screws (14) (as shown in figure). Be sure the plunger of the theft deterrent switch will engage with the cam surface of the cylinder (1) and is securely attached to the case.

Instrument Panel Compartment Door Lock Cylinder





The internal lock cylinder only uses 4 of the ten cut positions, 7 through 10. The tumbler positions are on one side and self-retaining.

1. Rotate the cylinder (1) so the side with tumbler spring wells faces up.
2. Insert the tumbler springs (2) into the 4 spring wells.
3. Install the first tumbler (3) for key cut position 7 in the slot nearest to the front of the lock cylinder. Install the remaining tumblers following the key code.
4. Press the tumblers in place until they are secure.
5. Check for correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flush with the lock cylinder body.