Locks: Service and Repair

Key and Lock Cylinder Coding

Ignition Lock Cylinder (Automatic Transmission)

The ignition lock cylinder uses only 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.




1. Hold the ignition cylinder assembly (1) so the side with the tumbler spring pocket located closest to the head of the cylinder is facing up.
2. Insert the tumbler spring (2) into each of the 4 spring pockets of the cylinder assembly (1).
3. The first tumbler (3) to be loaded will be the second key cut position, which is the second number in the key code. Install the first tumbler in the slot over the spring. Install the remaining tumblers following the key code and same process, pressing the tumblers in place until they are secure.
4. Rotate the cylinder assembly (1). Insert the tumbler spring (2) into each of the spring pockets of the cylinder assembly.
5. The first tumbler 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 and 7 following the key code and 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. All tumblers should drop flush with the lock cylinder body diameter.
7. Lightly lubricate the outside surface 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. With the key in the cylinder assembly (1), insert the actuator (4) in the actuator pocket and hold. Rotate the cylinder assembly and insert the retainer spring (6) in the retainer slot located in the cylinder assembly. Insert the retainer (7) lining it up in the slot over the spring. Depress the retainer and hold.
9. Insert the cylinder (1) into the sleeve (5) as shown in the illustration. Make sure the actuator stays located properly in the cylinder.
10. When the key is removed the sleeve (5) should stay on the cylinder (1).
11. Insert the key and function the lock 3 times to distribute the grease inside the sleeve.
12. Verify the key position for inserting the lock into the column.

Ignition Lock Cylinder (Manual Transmission)





The ignition lock cylinder uses only 9 of the 10 cut positions, 2-9. The ignition cylinder tumblers (2) are all located on one side of the cylinder (1) and not self-retaining. A retainer (4) secures the tumblers. It follows the key code with the first tumbler being the first depth of the key code.

1. Hold the ignition cylinder (1) so that the side with the tumbler spring wells is facing up.
2. The first tumbler (2) to be loaded will be the second key cut position, the second number in the key code. Install the first tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code.
3. Insert tumbler springs (3) into the wells on top of the tumblers.
4. Assemble the retainer (4) over springs. Secure by moving cylinder material over edges of the retainer with either a flat head screwdriver or a center punch on each of the four corners over the ends of the retainer.
5. Inspect for correct loading of the tumblers by inserting the key into the cylinder. The side bar (5) should drop flush with the lock cylinder body diameter.
6. Lightly lubricate the outside surfaces in the tumbler area of the lock body and down the key slot using the supplied grease. Insert and extract the key 5 times to lubricate the keyway.
7. Line-up the lock to the run position. Insert lock in steering column making sure the retainer (6) is seated properly. Rotate 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 column housing inside diameter.

Front Side Door Lock Cylinder

The front side door lock cylinder uses 7 of the 10 key cut positions, 4-10 when counting from the key head. The tumbler orientations alternate in adjacent locations from side to side with 4 on each side.





Note: The front side 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 assembly (4).

1. Hold the uncoded cylinder (1) positioned so the side with 4 tumbler spring holes is facing upward, as shown.
2. Insert one tumbler spring (2) each into the 4 tumbler spring holes.
3. The first tumbler to be loaded will be key cut position 4, the fourth 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 3 remaining tumblers (3) into the tumbler slots located at key cut positions 6, 8, and 10.
5. 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.
6. Rotate the cylinder (1) so that the side with 3 tumbler spring holes is facing downward and then remove the matching key. Remember the tumblers (3) are not self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 3 tumbler spring holes.
8. The first tumbler to be loaded will be key cut position 5. Determine the cut depth at this 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 3 remaining tumblers (3) into the tumbler slots located at key cut positions 7 and 9.
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) surfaces using the lubrication provided.
12. Hold the case assembly (4) with the pre-staked detent spring retainer facing downward.
13. First insert one detent spring (5) and then one detent ball (6) into the detent spring hole located to the rear and inside of the cylinder case assembly (4). The detent spring and detent ball are not self-retaining and must be held in place until the coded cylinder is installed into the case assembly.

Warning

Wear safety glasses in order to avoid eye damage.

14. With the matching key fully inserted into the coded cylinder, install the coded cylinder into the case assembly (4). Make sure the detent spring (5) and detent ball (6) are held in place until the coded cylinder is fully installed. The detent ball should line up with the V-shaped groove on the rear of the cylinder, which will prevent the detent spring and detent ball from falling out of the case assembly.
15. Remove the matching key being careful to keep the coded cylinder (1) fully inserted into the case assembly (4).
16. Insert one shutter spring (7) each into the 2 shutter spring holes located on the front face of the cylinder (1).
17. Install the shutter assembly (8) into the recessed area on the front face of the cylinder (1). Be sure that the ends of the pin on the shutter assembly are positioned in the pin cavities located in the front face of the cylinder.
18. Install the lock cylinder cap (9) by aligning the drain hole in the cap with the bottom of the case assembly (4). Snap the cap into place with light hand pressure. Be sure the cap is securely retained on the case assembly. Also, be sure that the shutter springs (7) push the shutter assembly (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).

Instrument Panel Compartment Door Lock Cylinder

The instrument panel (I/P) compartment door lock cylinder uses 4 of the 10 key cut positions, 7-10 when counting from the key head. The tumbler orientations alternate in adjacent locations with all 4 tumblers (3) located on the same side. A stainless steel retaining tumbler is used in the I/P compartment door lock cylinder to retain the lock cylinder in the latch assembly and does not move when the key is inserted. The retaining tumbler is located in the tumbler slot closest to the head of the cylinder assembly (1) and comes pre-installed in the cylinder.




1. Hold the uncoded cylinder assembly (1) positioned so the side with 4 tumbler spring holes is facing upward.
2. Insert one tumbler spring (2) each into the 4 tumbler spring holes.
3. The first tumbler to be loaded will be key cut position 7, the seventh 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 cylinder assembly (1), the end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3 remaining tumblers (3) into the tumbler slots located at key cut positions 8, 9 and 10.
5. Snap the tumblers (3) into place with light hand pressure.
6. Check for correct tumbler loading by fully inserting the matching key into the cylinder (1). All tumblers (3) should be flush with the outside diameter of the cylinder.