I sure hope someone can offer advice. The key/ignition cylinder on our 1991 Ford Ranger has broke somehow so we cannot even get the key into the ignition. The key doesn't have any broken parts off it, so am not sure what is inside the cylinder. We purchased a new ignition cylinder but the trouble is that all the instructions we've seen on replacing the cylinder say in order to take the old cylinder out, you have to have a key in the ignition in the 'on' position and we can't get a key into it due to whatever is inside there. How can we get the cylinder out without having a key in it? Any help greatly appreciated!

 

Welcome to FTE!!!

Lock Cylinder Non-Functional

Removal

NOTE: The following procedure applies to vehicles in which the ignition lock is inoperative and the ignition switch lock cylinder (11582) cannot be rotated due to a lost or broken key, unknown key number, or a cap that has been damaged or broken to the extent that the ignition switch lock cylinder cannot be rotated.



Disconnect battery ground cable.

Using channel lock or vise grip pliers, twist cap until it separates from the ignition switch lock cylinder.

Remove lower shroud as outlined in this section under shroud removal.

*****-punch pin and drill out with 1/8-inch bit. Do not drill deeper than 13mm (1/2 inch). Put a piece of masking tape 13mm (1/2 inch) from tip on bit. Take care not to damage housing.

Using a 3/8-inch diameter drill, drill down middle of ignition lock key slot approximately 44mm (1-3/4 inch) until ignition switch lock cylinder breaks loose from breakaway base of ignition switch lock cylinder. Remove ignition switch lock cylinder and drill shavings from lock cylinder housing.

Remove column lock gear retainer, steering column lock housing bearing (3E700) and steering column lock gear (3E717). Thoroughly clean all drill shavings and other foreign materials from lock cylinder housing.

Carefully inspect lock cylinder housing for damage from the above operation. If damage is apparent, lock cylinder housing must be replaced.

Installation

Replace lock cylinder housing, if damaged.

Install steering column lock gear, steering column lock housing bearing and column lock gear retainer.

Install trim and electrical parts.

Install new ignition switch lock cylinder as described in this section.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.



Connect battery ground cable.

Check operation of lock cylinder.

 

Have a look inside the lock where the key goes. You may need a light. Look for any part of the assembly that appears to have "dropped" which would prevent the key from going in.
Get a long safety pin (not too thick) and straighten it out. Use the pin to hold the "dropped" part up while you put the key in.
Kind of a long shot, but I've done a few over the years.

 

Get a large drill bit.

Just kidding.

 

Thanks for all the tips. Tried putting a paper clip in to see if I could move whatever it is. Will print out Ken00's instructions and have to go that route. Very annoying to have a perfectly running truck but you can't start it. Even more annoying is it's my 16 yr old son's truck and instead of hearing 'are we there yet' (like when he was young) now I hear when will my truck be fixed everyday. Thanks!!