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VW MKIII-A3/B4 TDIs This is a discussion about MKIII-A3/MkIII Jetta/Golf (<99.5) and B4 Passats (96,97) TDI's. Non TDI related postings will be moved or removed.

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Old January 3rd, 2004, 16:32   #1
BioDiesel
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TDI(s): '98 Jetta
Default Ignition switch replacement - Remove collar w/????

Hi TDI'ers,

I'm in the process of replacing my faulty ignition switch contacts. But I can't get the steering wheel collar off.

Other posters have mentioned using a puller, and the Bently manual refers to a 2-armed special puller. I've tried a std gear puller with a 'Posi-lock' clamp that holds the fingers tight, but they still slip off. There is only a 1/16 of an inch lip to pull. Mine is getting gouged.

Anyone know what the VW mechanics use?

Thanks in advance.
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Old January 3rd, 2004, 17:28   #2
Beetlebat
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Default Ignition switch replacement - Remove collar w/????

I just finished my ignition switch replacement a few minutes ago. I had fun with the adapter/collar as well. I've heard there is a tool, but I couldn't find it. I used a galv. fence post clamp on mine and it worked for me.
I bought a 1 3/8" metal fence post clamp at Home Depot. (The adapter is actual 1 1/16" diameter). I was able to tighten the clamp around the adapter and it held nicely, did not slip over the lip. I used a three leg puller from AutoZone that they 'rent'(pay for it and get a refund when you return it). It still took me a while and several attempts but it finally came off. I did squirt some penetrating oil on the fitting to help loosen it, I don't know if this helped or not. It's a tight fit since it is a press fit only on the steering column, no splines.
Email me if you need more help on the fence clamp!
Good luck. After the adapter is off it's a piece of cake. Instead of drilling out the 'shear bolt' that secures the ignition housing on, I cut a screw driver slot with a Dremel cutting wheel. I removed and reused it since my local dealer doesn't even have one in stock.
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Old January 3rd, 2004, 20:27   #3
BioDiesel
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Default Ignition switch replacement - Remove collar w/????

Thanks for sharing your clever clamp Beetlebat!
I too rented the 3-legged "Posi-Lock" puller from Autozone.
I'll head off to Home-Depot tommorrow. If I need help, I'll email you.

Thanks for taking the time to help me out.

JIm
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Old January 7th, 2004, 16:18   #4
BioDiesel
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Default Ignition switch replacement - Remove collar w/????

Finally got the steering column adapter/collar off!
The 2 piece collar worked great. Just clamped it down behind the adapter land, amd attached the gear puller and with a little grunting, it pop'd off.

I used a 2 piece 1 1/16" clamp type shaft collar from www.mscdirect.com. They have 3 PN's. In increasing price they are:
87990693,35461094,87991733

The -0693 PN was $4.50 , plus shipping.

The attached picture shows the 4 relevent items.
On the top is the 'Posi-Lock' Gear puller from Autozone.
Lower left is the steering adapter/collar showing the tiny land [img]/images/graemlins/frown.gif[/img].
Lower middle is the 1 1/16" 2 piece shaft collar.
Lower right is the 1 3/8" fencing clamp.



Luckily, my shear bolt was loose, so I won't have to use an 'easyout' screw extractor, or cut a slot in it with a Dremel tool to get it out.

After this I should be able to remove the ignition switch assembly and unscrew the screw holding the contact assembly and put in the new contacts.

Email me at the address in my signature if you have questions, or want to borrow the 2 piece clamp.

Jim
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Old September 1st, 2012, 21:50   #5
BakoTDI
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Does a faulty ignition switch cause the irritating moments in which you think your battery might be dead, except for the fact that it is NOT and all your electrical components work perfectly? I have experienced this in several occasions, but after a few tries of turning the key, the engine comes on and I'm on my way. However, tonight, I cannot get the engine to come on. All my indicator lights come on as normal except for the engine doing absolutely nothing!! I had to push my car into my garage.

Am I on the right track here with the ignition switch being the culprit??

Your direction on this matter will be greatly appreciated!
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Old September 2nd, 2012, 08:22   #6
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Before condemning the ignition switch, ensure all grounds are clean and tight. You may have to remove the battery to do it right. Check connections at the starter as well.
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Old September 2nd, 2012, 09:16   #7
Chris Bell
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Quote:
Originally Posted by BigBearTDI View Post
Does a faulty ignition switch cause the irritating moments in which you think your battery might be dead, except for the fact that it is NOT and all your electrical components work perfectly? I have experienced this in several occasions, but after a few tries of turning the key, the engine comes on and I'm on my way. However, tonight, I cannot get the engine to come on. All my indicator lights come on as normal except for the engine doing absolutely nothing!! I had to push my car into my garage.

Am I on the right track here with the ignition switch being the culprit??

Your direction on this matter will be greatly appreciated!
If this is for your '99 Mk. 4, post in the A4 section
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Old September 2nd, 2012, 12:02   #8
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Quote:
Originally Posted by Chris Bell View Post
If this is for your '99 Mk. 4, post in the A4 section

As a matter of fact it is and I didn't notice the forum until after the fact. I will research in the proper place. Thank you
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Old September 2nd, 2012, 12:04   #9
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Quote:
Originally Posted by Yblocker View Post
Before condemning the ignition switch, ensure all grounds are clean and tight. You may have to remove the battery to do it right. Check connections at the starter as well.

Ok, I will try this! I have checked the battery terminals to make sure that they are making good contact but that made no difference. Although, I did get a click after a few attempts. Is this a clue?
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Old September 2nd, 2012, 16:35   #10
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Stupid question, but how's the battery? Sometimes the break quickly.
Check voltage, and check voltage when trying to crank.
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Old September 5th, 2012, 08:28   #11
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battery is good. i even tried jumping it but there is no indication that battery might be weak. when i turned the key, there was nothing going on in the engine other than the usual glow plugs, but no cranking at all. just as if the battery was dead, except for the fact that my radio and accessories all work, all lights come on, all chimes come on , etc. puzzling. gonna try the relay 109.
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Old September 5th, 2012, 11:42   #12
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Probably not the 109 - it doesn't affect the starter.

Switch, cables, starter motor. You did check the voltage?
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Old September 6th, 2012, 19:51   #13
BakoTDI
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Not relay (check)
Next will be the ignition switch. Ugh!!
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Old September 6th, 2012, 19:55   #14
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Quote:
Originally Posted by rdkern View Post
Probably not the 109 - it doesn't affect the starter.

Switch, cables, starter motor. You did check the voltage?
Weird thing is that earlier in the day when this issue first happened, i had problems starting it. What happened was that the battery clicked then the next try, it started. I guess I will get starter checked as well and batter voltage.
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