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    Ford Thunderbird/Cougar 1983-1997 Repair Guide

    Ignition Lock Cylinder

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    REMOVAL & INSTALLATION



    Functioning Lock Cylinder

    The following procedures apply to vehicles that have functional ignition switch lock cylinders. Lock cylinder keys are available for these vehicles, or the lock cylinder key numbers are known and the proper key can be made.

    1983-93 VEHICLES

    See Figures 1 and 2

    1. Disconnect the negative battery cable.
    2.  
    3. On tilt columns, remove the upper extension shroud by unsnapping the shroud from the retaining clip at the 9 o'clock position.
    4.  
    5. Remove the trim shroud halves.
    6.  
    7. Unplug the wire connector at the key warning switch.
    8.  
    9. Place the shift lever in PARK and turn the key to RUN.
    10.  
    11. Place a 1 / 8 in. (3mm) wire pin in the hole in the casting surrounding the lock cylinder and depress the retaining pin while pulling out on the cylinder.
    12.  



    Click image to see an enlarged view

    Fig. Fig. 1: Lock cylinder replacement on vehicles equipped with tilt column-1983-93 vehicles



    Click image to see an enlarged view

    Fig. Fig. 2: Lock cylinder replacement on vehicles equipped with a fixed column-1983-93 vehicles

    To install:
    1. When installing the cylinder, turn the lock cylinder to the RUN position and depress the retaining pin, then insert the lock cylinder into its housing in the flange casting. Assure that the cylinder is fully seated and aligned in the interlocking washer before turning the key to the OFF position. This will allow the cylinder retaining pin to extend into the cylinder cast housing hole.
    2.  
    3. The remainder of installation is the reverse of the removal procedure.
    4.  
    5. Connect the negative battery cable and check for proper operation.
    6.  

    1994-96 VEHICLES

    See Figure 3

    1. Disconnect the negative battery cable.
    2.  
    3. Turn the ignition switch lock cylinder to the RUN position.
    4.  
    5. Place a 1 / 8 in. (3.17mm) diameter wire pin or small drift punch in the hole in the upper steering column shroud under the ignition switch lock cylinder. Press the retaining pin while pulling out of the ignition switch lock cylinder to remove it from the steering column tube flange.
    6.  

    To install:
    1. Install the ignition lock cylinder by turning it to the RUN position and pressing the retaining pin. Insert the ignition lock cylinder into the steering column tube flange. Make sure the lock cylinder is fully seated and aligned in the interlocking washer before turning the key to the OFF position. This will permit the cylinder retaining pin to extend into the steering column tube flange hole.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 3: Depress the retaining pin, turn the lock cylinder to the RUN position, then install the lock cylinder

    1. Rotate the ignition lock cylinder, using the ignition key, to ensure correct mechanical operation in all positions.
    2.  
    3. Connect the negative battery cable.
    4.  

    Non-Functioning Lock Cylinder

    The following procedure applies to vehicles in which the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken lock key, the key number is not known, or the lock cap is damaged and/or broken to the extent

    that the lock cylinder cannot be rotated.

    1983-93 VEHICLES
    1. Disconnect the battery ground.
    2.  
    3. Remove the steering wheel.
    4.  
    5. On tilt columns, remove the upper extension shroud by unsnapping the shroud from the retaining clip at the 9 o'clock position.
    6.  
    7. Remove the steering column trim shrouds.
    8.  
    9. Disconnect the wiring at the key warning switch.
    10.  
    11. Using a 1 / 8 in. (3mm) drill bit, mounted in a right angle drive drill adapter, drill out the retaining pin, going no deeper than 1 / 2 in. (13mm).
    12.  
    13. Tilt the column to the full down position. Place a chisel at the base of the ignition lock cylinder cap and using a hammer, break away the cap from the lock cylinder.
    14.  
    15. Using a 3 / 8 in. (9.5mm) drill bit, drill down the center of the ignition lock cylinder key slot about 1 3 / 4 in. (44mm), until the lock cylinder breaks loose from the steering column cover casting.
    16.  
    17. Remove the lock cylinder and the drill shavings from the housing.
    18.  
    19. Remove the upper bearing snapring washer and steering column lock gear.
    20.  
    21. Carefully inspect the steering column housing for signs of damage from the previous operation. If any damage is apparent, the components should be replaced.
    22.  
    23. Installation is the reverse of removal.
    24.  

    1994-96 VEHICLES
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the steering wheel, as outlined earlier in this section.
    4.  
    5. Using suitable locking pliers, twist the ignition switch cap or bezel until it separates from the lock cylinder.
    6.  
    7. Using a 3 / 8 in. drill bit, drill down the middle of the key slot approximately 1 3 / 4 in. (44mm) until the lock cylinder breaks loose from the breakaway base of the lock cylinder. Remove the lock cylinder and drill shavings from the steering column tube flange.
    8.  
    9. Remove the steering column upper bearing retainer, steering column lock housing and bearing, ignition switch lock cylinder and steering column lock gear. Thoroughly clean all drill shavings and other foreign materials from the casting.
    10.  
    11. Carefully inspect the steering column tube flange for damage. If there is damage, the steering column tube flange must be replaced.
    12.  

    To install:
    1. If necessary, replace the steering column tube flange.
    2.  
    3. Install the steering column lock gear and ignition switch lock cylinder.
    4.  
    5. Install the trim and electrical parts.
    6.  
    7. Install a new ignition switch lock cylinder as outlined earlier in this section.
    8.  
    9. Install the steering wheel.
    10.  
    11. Connect the negative battery cable, then check the lock cylinder for proper operation.
    12.  

     
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