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1987 - 1996 F150 & Larger F-Series Trucks 1987 - 1996 Ford F-150, F-250, F-350 and larger pickups - including the 1997 heavy-duty F250/F350+ trucks

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Old 03-07-2008, 12:07 PM
chuck460 chuck460 is offline
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91 f150 ignition switch replacement

I am replacing my steering column with one from a junk yard. I don't have the key to the one from the junk yard and was wondering how hard it would be to drill out the ignition switch and replace it with a new one. I talked to a guy at a lock shop who told me it would have to be drilled. So i thought i would attempt it myself instead. Has anyone on here done this? Thanks Chuck
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Old 03-07-2008, 12:27 PM
mhg mhg is offline
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it just takes time and care
be gentle and it will come out
will need to use small bits and drill several holes
once you get the tumblers out you can turn the sleeve
and use the normal removal procedure
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Old 03-07-2008, 12:29 PM
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i posted about 3 months ago how ford manual says to do if key broke off or lost keys to get cylinder out. here it is again:

-disconnect battery ground cable.

-remove steering wheel.

-using channel lock pliers or vise grips, twist lock cylinder cap until it seperates from the lock cylinder.

-using a 3/8" diameter drill, drill down middle of ignition key slot approx. 44mm (1-3/4") until lock cylinder breaks loose from breakaway base of lock cylinder. remove lock cyl. and drill shavings from the lock cylinder housing.

-remove retainer, washer, ignition switch and actuator. thoroughly clean drill shavings and all other foreign materials from casting.

-carefully inspect lock cyl. housing for damage from the above operation. if damage is apparent, housing must be replaced.


to install your new lock cylinder should have instructions.

good luck!
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Old 03-07-2008, 01:16 PM
chuck460 chuck460 is offline
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Thanks for the quick response! I'm going to give it a try. Chuck
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Old 03-07-2008, 01:17 PM
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FYI that is not the ignition switch - that's the ignition lock cylinder you are working on.
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Old 03-07-2008, 02:55 PM
chuck460 chuck460 is offline
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Thanks Jas88, I wasn't sure what it actually was called. I guess the actual ignition switch is located at the end of the linkage rod located a little further down the column. Now i know what to ask for when i'm standing at the parts counter. Chuck
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Old 03-07-2008, 03:14 PM
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the key/lock cylinder is what you need.

the ignition actuator is the electrical part down the column.
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Old 03-10-2008, 09:00 AM
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Quote:
the ignition actuator is the electrical part down the column.
This is not correct. He had it right. The ignition switch is located up on top of the column down towards the firewall.

The actuator is not an electrical part. It's inside the column just behind the steering wheel. There are actually 2 parts in there that Ford calls the "actuator". One is the pot metal hook looking thing that breaks all the time, the other is the toothed arm that meshes with the gear on the end of the lock cylinder.
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Old 05-25-2009, 01:22 PM
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Hey all,

I have much the same situation going on here. I lost my ignition key to my F250 recently. Therefore I'm trying to get the lock cylinder out of the truck so i can bring it to a locksmith to get a key made. OR... depending on the cost of a new lock cylinder with key, just buy one and install it.

Currently i've taken apart the steering column as much as i can. I cant pull the steering wheel because it's not coming off with human force. I guess i need a steering wheel puller. See the picture below to see where i'm at. Is there any way for me to get the lock cylinder out without the key and without drilling down the center of it? I feel like if i do that i'm going to damage it.

thanks for any help you can provide.
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Old 05-26-2009, 08:47 AM
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Put the nut back on the wheel but leave a gap between the nut and the wheel. Then muscle up and press your back against the seat as hard as you can, planting your feet on the floorboard behind the brake pedal. Using both hands at 9 and 3 o'clock, pulll as hard as you can while rocking the wheel side to side. I have pulled many wheels this way when I didn't have a puller handy and it always has worked for me. Just be sure to put the nut back on first or you will be wearing the wheel around your neck when it breaks loose.
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Old 05-26-2009, 09:56 AM
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i do not see any benefit to having the steering wheel off.

drill like i posted before.

or have a locksmith come over and do the same thing, for $100.
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Old 10-14-2012, 04:15 PM
Nigel Miller Nigel Miller is offline
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Found the board this weekend and have been reading through posts on removing the ignition switch. I hate to ask for help with out contributing but I'm out of ideas.

I lost the keys for my '88 F-250 and my local mechanic gave me instructions which were similar to quicklook2's.

However, the local mechanic did not recommend removing the steering wheel. Is that absolutely necessary? I have drilled out and removed the lock cylinder and the pin with a 1/8th drill. However, I can not pull out the cylinder. Any recommendations?

Thanks in advance.
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Old 10-14-2012, 04:15 PM
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