Locks: Service and Repair

Key and Lock Cylinder Coding

Special Tools

BO-48370 - Lock Cylinder Cap Installer

Ignition Lock Cylinder





The ignition lock cylinder uses only 7 of the 10 cut positions, 3 through 9. The ignition cylinder tumblers are all 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 4 tumblers spring pocket of the cylinder is facing up.

2. Insert the tumbler springs (2) into each of the spring pockets of the cylinder assembly.

3. 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 nearest the head of the lock cylinder. Install the remaining tumblers for cuts 5, 7 and 9 following the key code and same process. Press the tumblers in place until they are secure.

4. Rotate cylinder assembly so the 3 tumblers springs pocket of the cylinder is facing up. Insert tumbler springs (2) into each of the spring pockets of the cylinder assembly.

5. The first tumbler (3) to be loaded will be the fourth key cut position, the fourth number in the key code. Install the first tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers for cuts 6 and 8 following the key code and same process. Press the tumblers in place until they are secure.

6. Inspect for correct loading of the tumblers by inserting the key into 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 lock in steering column. Rotate lock to key out position and remove key. Insert key and rotate 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 8 of the 10 key cut positions, 3 through 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 in not fully inserted into the lock cylinder or until the cylinder (1) is assembled into the case assembly (4). Left side shown, right side opposite.

1. Hold the uncoded cylinder (1) positioned so the side with the rotational stop lug 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 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 (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 5, 7, and 9.

5. Check the 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 the side with the rotational stop lug 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 4 tumbler spring holes.

8. The first tumbler to be loaded will be key cut position number 4. Determine the cut depth at this position and install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder assembly.

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 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 the tumbler (3) surfaces using the lubrication provided.

12. Hold the case assembly (4), left side shown, right side opposite, 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 two 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), left side shown, right side opposite, 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.

Rear Compartment Lid Lock Cylinder - Police Vehicles 9C1 and 9C3

The rear compartment lid lock cylinder uses 8 of the 10 key cut positions, 3-10 when counting from the key head. The tumbler orientations alternate in adjacent locations from side to side with 4 on each side.





Note: The rear compartment lid 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 uncoded cylinder (1) positioned so the side with the drain hole is facing downward.

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 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 cylinder (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 5, 7, and 9.

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 the drain hole is facing upward 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 4 tumbler spring holes.

8. The first tumbler to be loaded will be key cut position number 4. Determine the cut depth at this position and install the corresponding tumbler (3) into the open 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 into the tumbler slots located at 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) surfaces using the lubrication provided.

12. With the matching key fully inserted into the coded cylinder, install the coded cylinder into the case (4).

13. Remove the matching key being careful to keep the coded cylinder (1) fully inserted into the case (4).

14. Insert one shutter spring (5) each into the 2 shutter spring holes located on the front face of the cylinder (1).

15. Install the shutter assembly (6) 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.

Note: Be careful not to scratch or dent the cosmetic surface of the cap or damage the lock cylinder in any way while staking the cap.

16. Stake the cap (7) onto the head of the case (4) by using the appropriate staking tool BO-48370 - lock cylinder cap installer. Ensure proper orientation and set the cylinder assembly (14), (which includes the case (4), coded cylinder (1), shutter springs (5), and shutter assembly (6)) and the cap (7) into the staking cup (15) and clamp into vise. Remove any debris and install the cleaned staking ram (16) into staking cup (15) and with a dead blow hammer, hit the staking ram (16) with moderate force 2 or 3 times. Check to determine if cap is securely staked to the cylinder assembly (14). Repeat previous step until cap is securely staked to the cylinder assembly. Remove assembly from the staking cup (15). If necessary, insert the removal punch (17) into the opposite end of the staking cup and tap lightly. Confirm that the shutter springs (5) push the shutter assembly (6) up against the inside surface of the cap (7).




17. Install the gasket (8) over the end of the cylinder assembly and slide it all the way up the case (4) until it seats behind the cap (7).

18. Install the return spring (9) over the back end of the cylinder (1) with the straight hook facing the rear of the case (4). Engage the straight hook of the return spring with the hook feature on the rear of the case.

19. Install the spacer (10) and lever (11) onto the end of the cylinder (1).

20. Install the retaining ring (12) in the groove at the end of the cylinder (1) to secure the lever (11) to the cylinder. Engage the bent hook of the return spring (9) with the lever.

21. Install the theft deterrent switch (13) onto the end of the cylinder (1) and snap the switch legs onto the case (4). Be sure the theft deterrent switch is engaged with the end of the cylinder and is securely attached to the case.

22. Check the operation of the lock assembly. The return spring (9) should provide a counterclockwise snap back.