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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 February 18th, 2004, 02:14   #1
sfierz
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Default ignition switch replacement

For those of you who have replaced a faulty ignition switch on a Passat, is it possible just to replace the electrical portion of the switch, not the whole assembly. What I am talking about replacing is:

http://www.impexfap.com/partlist.cfm?get...y=4300#part6136

There seems to be some confusion on this. Some people have replaced the whole assembly (removing the steering wheel), others may have just replaced this part. I would like to be able just to pull this part and replace. This would not necesitate removing the steering wheel, just pulling the lock. Can this be done effectively?
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Old February 18th, 2004, 04:50   #2
oilhammer
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Default ignition switch replacement

sfierz, you'll need to pull it all apart anyways, the screw that holds the electrical portion in is underneath it all.

You'll need a couple special puller tools to get the collar off of the upper steering column.

If you like, you could make a trip down my way (Union, Missouri) some weekend and I can help you out. That is a pretty long trip, as I remember Dekalb is near Chicago.
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Old February 18th, 2004, 08:27   #3
BKmetz
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Default ignition switch replacement


I just went through ignition switch hell on my Passat a few weeks ago.

You have to remove the whole steering column lock assembly from the steering column to get the ignition switch off the back. The hard way is to pull the collar off. The easy way is to buy a new collar and cut the old one off with a Dremel tool. Then just install the new collar during assembly.

I was having ignition switch problems almost two years ago. At that time I ordered a new ignition switch and tried to get the collar off the steering column. No luck. Every type of puller I tried couldn't grip the collar enough to budge it. I did the Gofaster WD-40 fix until I could find a better puller. That worked for almost two years. In the meantime I bought a new key lock too. My key was getting really sloppy in the lock. So the plan was to wait for the ignition switch to act up again and replace everything while I had it all apart.

Well, the ignition switch did start acting up again. The WD-40 fix no longer worked. But this time I was better prepared. I had the new collar as a back-up if I couldn't pull the old one off. A new collar is less than $10 from the dealer.

I spent over an hour messing around trying to get a puller to fit, and then using large C-clamps to hold the fingers of the puller tight. No matter, it always slipped. I then used the Dremel tool to cut slots on two sides of the collar so the puller would have more area to grab on to. All I did was strip the edge of the collar off where I cut the slots. I was beginning to think the damn collar was friction welded to the steering column from the factory.

New plan: death to the old collar. I cut a slit down the length of the collar about 1 inch long, almost cutting into the steering column. The slit took about 45 seconds to cut with the Dremel tool. Then I took an old screwdriver and pounded it into the slit. When the screwdriver was wedged in the slit tightly I wigged it back and fourth until it worked loose. I repeated this step a few times until the collar stretched, became loose, and almost fell off the steering column. I was worried the spring would pop off the collar and hit me or part of the car. This did not happen.

Time spent trying to pull the collar off with several types of pullers: at least two hours, with no success. Time spent cutting and spreading the collar: in about five minutes that collar was off the steering column.

After the collar and spring is off it takes about 1 minute to get the metal steering lock assembly off the column. Remove one Allen-head bolt and unplug the ignition switch. Then simply slide the whole assembly off the steering column.

It takes about 2 minutes to swap out the ignition switches. To help the new ignition switch line up and seat correctly in the lock housing and with the cam on the back of the key-lock, put the key in and turn it. The switch and key-lock do not automatically line up.

Putting it all back together is the opposite of how you took it apart. To get the switch/lock assembly to slide down the steering column easier, insert the key and turn it while sliding back down. This is to get the steel locking pin to retract. Otherwise the pin is in the way.

Special extra instructions if you plan to install a new key-lock. When you buy a new key-lock you will get new keys. This means you will have one set of keys to lock/unlock your car and another set to start it. I found this unacceptable. I found a locksmith who could take the lock apart and change the tumblers to match my original keys. This took a week and cost me about $35.

To remove the lock from the aluminum steering column lock/switch assembly, you have to drill a hole in it. After you drill the hole you insert some small tool to push in a spring that is holding the lock in. This spring is built into the key-lock. The drill bit you just used will work fine, I used a thin awl. The Bentley manual has an illustration as to where the hole is to be drilled. The illustration is vague, you might get the hole right the first time, you might not. After you get the old lock out, the new one slides right back in. Then you procede to install the new igition switch.

Sorry I didn't have a digital camera with me. A picture is really worth a thousand words with this job.

Brian, 97 Passat TDI
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Old February 18th, 2004, 10:20   #4
Metalnerd
 
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Default ignition switch replacement

No, we don't have a tool for that yet but I used a large, curved jaw, pair of vice grips to grab (lightly) behind the collar. Then I used a large 2 arm puller to grab the perimeter of the vice grip jaws.

There is not enough lip to use the pullers in the normal fashion but with the vice grips provide enough edges to grab the collar.
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Old February 18th, 2004, 12:37   #5
oilhammer
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Default ignition switch replacement

A bearing splitter works PERFECT for holding the collar, then I use a simple puller on the splitter. I've done dozens of VW ignition switches this way, works great.
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Old February 21st, 2004, 10:44   #6
BioDiesel
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Default ignition switch replacement

Here's a post on how I did mine:
Collar removal
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Old February 23rd, 2004, 19:24   #7
sassyrel
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Default ignition switch replacement

hey oilhammer--ive got a splitter for my press that is 8 x 8 in closed --spose this is big enough????? [img]/images/graemlins/grin.gif[/img] [img]/images/graemlins/grin.gif[/img] [img]/images/graemlins/grin.gif[/img]
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Old February 24th, 2004, 15:52   #8
oilhammer
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Default ignition switch replacement

[ QUOTE ]
hey oilhammer--ive got a splitter for my press that is 8 x 8 in closed --spose this is big enough????? [img]/images/graemlins/grin.gif[/img] [img]/images/graemlins/grin.gif[/img] [img]/images/graemlins/grin.gif[/img]

[/ QUOTE ]

[img]/images/graemlins/laugh.gif[/img] [img]/images/graemlins/eek.gif[/img]
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Old February 25th, 2004, 21:17   #9
N2TOH
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Default ignition switch replacement

The switch and lock were replaced already when I bought my Passat.

Does anyone know a locksmith that can rekey the lock cylinder to my original key? I worked as a locksmith, and every other company I have contacted in New Jersey can not get the parts.
[img]/images/graemlins/mad.gif[/img]


[ QUOTE ]
For those of you who have replaced a faulty ignition switch on a Passat, is it possible just to replace the electrical portion of the switch, not the whole assembly. What I am talking about replacing is:

http://www.impexfap.com/partlist.cfm?get...y=4300#part6136

There seems to be some confusion on this. Some people have replaced the whole assembly (removing the steering wheel), others may have just replaced this part. I would like to be able just to pull this part and replace. This would not necesitate removing the steering wheel, just pulling the lock. Can this be done effectively?

[/ QUOTE ]
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Old February 26th, 2004, 07:35   #10
BKmetz
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Default ignition switch replacement


The tumblers in the lock can be changed to work with your original keys. I found a local locksmith who did it. However, you have to remove the lock from the steering column lock assembly. The tumblers cannot be changed with the lock in the car. That means pulling everything off the steering column again. You have to drill one small hole in the steering column lock assembly to get the lock to come out.

If you are willing to go through the trouble of removing the steering column lock assembly and remove the lock from it, I'll email you the name, address, and phone number of the locksmith who changed my tumblers to work with my original keys.

Brian, 97 Passat TDI
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Old February 26th, 2004, 14:31   #11
N2TOH
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Default ignition switch replacement

[ QUOTE ]

The tumblers in the lock can be changed to work with your original keys. I found a local locksmith who did it. However, you have to remove the lock from the steering column lock assembly. The tumblers cannot be changed with the lock in the car. That means pulling everything off the steering column again. You have to drill one small hole in the steering column lock assembly to get the lock to come out.

If you are willing to go through the trouble of removing the steering column lock assembly and remove the lock from it, I'll email you the name, address, and phone number of the locksmith who changed my tumblers to work with my original keys.

Brian, 97 Passat TDI

[/ QUOTE ]

The hole has already been drilled, It takes me about 2 min to remove the cylinder. All I need to do it is a ballpoint pen and a screwdriver.
[img]/images/graemlins/tongue.gif[/img]
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Old February 26th, 2004, 15:05   #12
BKmetz
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Default ignition switch replacement


Oh, OK. With the little hole already drilled then it would only take about 2 minutes to get the lock out.

The black metal bezel ring around the key hole is pressed into lock/tumbler assembly. It is ruined when it comes off, and it has to come off to change the tumblers. The locksmith has to order a new bezel ring. This made my wait about 5 days. Once the locksmith has the new bezel ring, he only needs a few hours to change out the tumblers.

So if you can spare your car being down for a week, I know a guy that can change your tumblers.

Brian, 97 Passat TDI
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Old February 27th, 2004, 14:23   #13
chudzikb
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Default ignition switch replacement

I read this and when my Indy said at inspection on Thursday that it needed a switch, I said absolutely intall it and bill me! Way less pain. Now if I could only bread down and take him the door....

BEC
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Old February 27th, 2004, 22:07   #14
sfierz
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Default ignition switch replacement

That may be what I end up doing as well. I don't really want to have to go to the trouble of ordering the part, having all those special tools, and freezing out in the garage for and hour just to remove/install it. I do have an OK setup of basic tools, but I don't have a Dremel tool and I don't want to have to drill anything out. On the good side, now that the weather is warmer, the switch is behaving normally again. It seems like it starts acting up when the temp is below 20F. I might be able to milk it for a few more months.--Steve
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Old February 28th, 2004, 14:13   #15
N2TOH
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Default ignition switch replacement

[ QUOTE ]

Oh, OK. With the little hole already drilled then it would only take about 2 minutes to get the lock out.

The black metal bezel ring around the key hole is pressed into lock/tumbler assembly. It is ruined when it comes off, and it has to come off to change the tumblers. The locksmith has to order a new bezel ring. This made my wait about 5 days. Once the locksmith has the new bezel ring, he only needs a few hours to change out the tumblers.

So if you can spare your car being down for a week, I know a guy that can change your tumblers.

Brian, 97 Passat TDI

[/ QUOTE ]

Ah reminds me of my Fraturinty party parking duty days. [img]/images/graemlins/rolleyes.gif[/img]

With the cylinder out I'll just use a screwdriver.
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