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Ignition Tumbler Replacement
 
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Pelican Technical Article:

Ignition Tumbler Replacement

Steve Vernon

Time:

4 hours4 hrs

Tab:

$75

Talent:

***

Tools:

24mm, 8mm socket, Philips head screwdriver, 1/8-inch drill bit

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

Tumbler

Hot Tip:

Be careful with aftermarket wires under the dash

Performance Gain:

Working ignition

Complementary Modification:

Clean all electrical connections

Replacing the ignition tumbler on a 1985 1/2 and newer Porsche 944 or 951 is not a quick job. The ignition tumbler, unlike other manufacturers, cannot be replaced without removing the entire ignition housing. Then you have to drill a release access hole in the housing to get the tumbler out. This is not a quick fix job. You will not be able to use the car while performing this work, so make sure you give yourself enough time and have all the parts you need. Also make sure that you have checked the condition of the switch portion first. While not a simple job changing out the switch is a lot easier than replacing the tumbler. Please see our article on ignition switch replacement for additional assistance.

You will need to first remove the steering wheel. Please see our article on steering wheel removal for additional information.

You are going to be removing the trim pieces on each side of the steering column (red arrows).
Figure 1

You are going to be removing the trim pieces on each side of the steering column (red arrows). You will also need to remove the instrument cluster (yellow arrow). Please see our article on instrument cluster removal for further assistance.

If you did not disconnect the battery to remove the steering wheel begin by disconnecting the ground cable from the post on the battery.
Figure 2

If you did not disconnect the battery to remove the steering wheel begin by disconnecting the ground cable from the post on the battery. This is also a good time to check the condition of the terminal and wiring, as our cable is starting to get a little corrosion (red arrow).

To replace the switches you will need to just remove the headlight switch from the trim piece, as you will need to remove the trim piece to get access to the fog and dimmer switches (yellow arrow).
Figure 3

To replace the switches you will need to just remove the headlight switch from the trim piece, as you will need to remove the trim piece to get access to the fog and dimmer switches (yellow arrow). The headlight switch is just to the left of the steering column. You can usually just pull the front of the switch straight off using only your hands (red arrow). If yours is on pretty firmly use a trim removal tool or a flathead screwdriver and gently pry the knob off.

The knob is just held in place by a friction fit (red arrow).
Figure 4

The knob is just held in place by a friction fit (red arrow). With the knob off you can see the 24mm washer holding the switch in place (yellow arrow).

Use a 24mm socket or a large set of pliers and remove the nut (red arrow).
Figure 5

Use a 24mm socket or a large set of pliers and remove the nut (red arrow). If you are using pliers take care not to mar the dash surface. With the nut off you can just push the headlight switch back and out of the trim piece.

With the steering wheel off use a Philips head screwdriver and remove the three screws on the column surround (red arrows).
Figure 6

With the steering wheel off use a Philips head screwdriver and remove the three screws on the column surround (red arrows).

Remove the column surround and use the Philips head screwdriver to remove the screws under and inside the column (red arrows).
Figure 7

Remove the column surround and use the Philips head screwdriver to remove the screws under and inside the column (red arrows).

Use a trim removal tool and pop off the trim piece beside the vent and remove the two Philips head screws (red arrows).
Figure 8

Use a trim removal tool and pop off the trim piece beside the vent and remove the two Philips head screws (red arrows).

Using a Philips head screwdriver remove the single screw on the end of the dash trim piece (red arrow).
Figure 9

Using a Philips head screwdriver remove the single screw on the end of the dash trim piece (red arrow).

Next, remove the three Philips head screws holding the switch trim piece and the vent (red arrows).
Figure 10

Next, remove the three Philips head screws holding the switch trim piece and the vent (red arrows). The vent is attached to the lower vent in the switch trim piece, so they have to be removed together.

With all the screws removed you can gently remove the trim piece from the dash.
Figure 11

With all the screws removed you can gently remove the trim piece from the dash.

Next, you are going to remove the trim piece from the other side of the steering column.
Figure 12

Next, you are going to remove the trim piece from the other side of the steering column. The trim piece is partially held in place by the HVAC control unit, so you will need to move it out of the way. Be very careful when prying the faceplate off of the unit. It is just held in by clips on the sides but they tend to break way too easily. Our project car's plate was already broken (red arrow) when we got the car.

Remove the knobs and sliders by pulling them straight off; you can probably do this with your hands for all of them but the fan speed control.
Figure 13

Remove the knobs and sliders by pulling them straight off; you can probably do this with your hands for all of them but the fan speed control. There is a small light behind the knob, so you want to make sure you take this knob straight off. I recommend you use a trim removal tool and gently pry it away from the faceplate (red arrow).

With the knob off you can see the small fragile bulb in the center (red arrow).
Figure 14

With the knob off you can see the small fragile bulb in the center (red arrow).

Use your trim removal tool and gently pry both ends of the plate off.
Figure 15

Use your trim removal tool and gently pry both ends of the plate off. Then work your way around until the complete plate is off. Take your time and go slow, as it will shock you how easy it is to break this plate.

With the plate off use a Philips head screwdriver and remove the four screws holding the unit in place (red arrows).
Figure 16

With the plate off use a Philips head screwdriver and remove the four screws holding the unit in place (red arrows).

Wiggle the unit out from the dash.
Figure 17

Wiggle the unit out from the dash. You do not need to disconnect it or remove it completely. You just need to move it enough so the trim piece can clear it.

Use a Philips head screwdriver to remove the screws under and inside the column (red arrows).
Figure 18

Use a Philips head screwdriver to remove the screws under and inside the column (red arrows).

Gently pry the trim piece out from the dash leaving the switches connected.
Figure 19

Gently pry the trim piece out from the dash leaving the switches connected. You can remove the rubber surround around the ignition tumbler (red arrow).

Looking from underneath you can see the two electrical connections (yellow arrows) and the 8mm bolt on the stalk switch (red arrow).
Figure 20

Looking from underneath you can see the two electrical connections (yellow arrows) and the 8mm bolt on the stalk switch (red arrow). Use an 8mm socket and loosen the bolt.

Slide the stalk switches forward while wiggling off the connectors (red arrow).
Figure 21

Slide the stalk switches forward while wiggling off the connectors (red arrow). There is not a lot of room to work. In addition, the connectors can be a little stubborn.

Reach in through the instrument cluster opening and wiggle and push the wiring harness off the back of the switch (yellow arrow).
Figure 22

Reach in through the instrument cluster opening and wiggle and push the wiring harness off the back of the switch (yellow arrow). Then disconnect the ignition buzzer switch (red arrow).

Working under the front of the dash you will need to remove the two sheer bolts holding the housing to the steering column (red arrows).
Figure 23

Working under the front of the dash you will need to remove the two sheer bolts holding the housing to the steering column (red arrows). The best way to do this is to tap, drill and then use an internal extractor to remove the bolts. With the bolts off remove the top plate and wiggle the housing out through the dash opening.

You are going to need to drill a small 1/8-inch hole in the housing to release the spring clip holding the tumbler in place.
Figure 24

You are going to need to drill a small 1/8-inch hole in the housing to release the spring clip holding the tumbler in place. Take the housing to your bench and measure the housing using this diagram and drill the 1/8-inch hole where the red arrow indicates.

With the key in the tumbler you can use the drill bit to push down on the spring where it will be sitting in the housing (red arrow).
Figure 25

With the key in the tumbler you can use the drill bit to push down on the spring where it will be sitting in the housing (red arrow). This will release the tumbler from the housing and allow you to pull it out by the key. Installation is the reverse of removal.


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Page last updated: Fri 12/9/2016 02:51:15 AM