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Replacing Ignition switch

C

cchristianson@ntlwor

New member
I am trying to replace the ignition switch on my 1987 944 because I have lost my ignition key. I have got to the point where I need to remove the two vertical bolts that clamp the ignition switch casting to the steering column. My Haynes manual says that these are removable by Allen key. However my bolts are "blind" bolts without a hexagon or Allen Key recess. There seems to be some metal filler inserted into the space that might take an Allen key. I assume I just have to drill this "filler" out or do I have to drill the complete bolt out. Any advice would be greatly appreciated.
 
Are you replacing the actual electric switch or the key barrel element? I've replaced the electrical switch and I don't recall any allen keys. Was a real PITA for access though. The bolts were a flat head screwdriver. I ended up using a 1/4" UJ fitting to get onto the head.
 
Scott, if the keys are lost the barrel needs to come out, Clive, you have a tough job on, the bolts you need to remove have the heads sheared off automatically when they are torqued up in the factory. And they are recessed as you say.
One good point is they should not be rusty.
I looked at this recently, found Scotts comment on replacing the switch and managed to do that without removing the barrel.
I think I would attempt to drill out the heads of the shear bolts?
Try Clarks or wait for some-one to respond - the answer will be easier than it looks.
good luck
George
944t
964
 
Ive recently replaced the ignition switch on my car, and yes, its a pain to get at the 2 rear screws, working back to front and blind!.

When I changed complete switches before that had the sheared screws in them, i found that a nicely sharpened small chisel would cut a slot big enough to allow you to use a plain screwdriver to get them out, (the added bonus of it is the shock from tapping against the bolts helps free them off a bit as well ).
good luck!
 
i just drilled mine started with a small drill and worked up in size easy job new shear bolts are cheap or you could use normal ones if you want i did

forgot to say this was a job i did on an old rover i had but should be the same
 
From (very long) memory, you only need to remove the bolts if you arent removing the ignition barrel. This isnt necessary, even if you dont have a key. Youll need to remove the steering wheel on a series two car and then work a large self tapping screw into the ignition barrel. When its securely in (about .5" - .75") fix a slide hammer / dent puller to the head. To pull the ignition barrel cleanly out you have to follow through after a very firm blow. The steering lock will be undamaged and youll be able to easily fit a replacement barrel.

Simon (retired Porsche thief)
 
If youre wary of taking my advice in the post above, then you can remove the shear bolts using a Dremel. Use two cutting discs on a flexible drive and you will be able to cut a slot whichll allow you to unscrew the bolts using a large screwdriver.

Simon
 
I would like to thank everyone who has replied to my posting about my lost key. Today, I have done the "bl***ing obvious" and ordered a new key from Auto 2000 in Bedford. If this does not work, I will try some of the other solutions that you have all recommended.

Many thanks

Clive C
 
ORIGINAL: cchristianson@ntlwor

I would like to thank everyone who has replied to my posting about my lost key. Today, I have done the "bl***ing obvious" and ordered a new key from Auto 2000 in Bedford. If this does not work, I will try some of the other solutions that you have all recommended.

Many thanks

Clive C
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