Ignition cylinder, assembly and switch HELP!

[Puma]

I ordered the parts for a new ignition and they arrived two days early! I would like to thank Pelican, FedEx and the Porsche Gods.

Now to the issues, I got the old ignition out of the car and it's sitting in front of me. I have a paper clip and the key in the ignition but I can't seem to get the lock out of the assembly. I've twisted, pulled, tugged and cussed extensively to no avail.

I also did something else that was probably stupid: I didn't disconnect the battery or run a signal wire before removing the gauge cluster, I only disconnected the left gauge wire and propped it out of the way. Did I cause some harm?

Thank you

[Wayne 962]

You should be fine on the gauge cluster.

The ignition key is tricky. Someone pointed out that my description in the book is confusion, to which I agree. I'll try to find the page in the manuals where this spells it out. Just spent about 10 minutes looking for it, but I couldn't find it...

-Wayne

[Puma]

Yay for not screwing up the gauge cluster!

I took it to a locksmith and he couldn't figure it out either, so now I have to get a new lock cylinder from Porsche and there isn't a dealer anywhere near where I live and I have to be present to get it. And they want a fortune for a cylinder that is keyed to my old key but who wants to carry around two keys?

Will the average locksmith be able to key my door lock to the new key?

In a related note, thanks Wayne for making the "101 Projects for Your Boxster" book. I now have two Boxsters to take care of so I actually bought two copies of the book. I know that sounds foolish but considering the money I've saved with this board it seems like a good idea to support it.

Thanks again,

Puma

[Wayne 962]

These instructions are correct, and should work:

To remove the ignition key cylinder, first begin by pulling out the rubber ignition switch surround (upper left). Then, turn the ignition switch to position 1 (ignition ON), and insert a large paper clip into the release hole in the key cylinder (shown by the orange arrow). Push the paper clip in as far as possible, insert the key, and that should release the mechanism and allow you to pull out the assembly. Finally, disconnect the small connector that attaches to the immobilizer induction coil (red arrow).

-Wayne

[Wayne 962]

Originally Posted by Puma

I took it to a locksmith and he couldn't figure it out either, so now I have to get a new lock cylinder from Porsche and there isn't a dealer anywhere near where I live and I have to be present to get it. And they want a fortune for a cylinder that is keyed to my old key but who wants to carry around two keys?

Will the average locksmith be able to key my door lock to the new key?

Seriously, I think this should simply pop out, unless I'm confused about what you're trying to accomplish? Maybe you need to use a bigger / longer paperclip?

-Wayne

[Wayne 962]

If you're not in a hurry to solve this problem, you can also mail it to me, and I will take a look at it. Although if a locksmith couldn't get it out, that's a pretty bad sign too.

-Wayne

[Puma]

Okay, I scored a new lock cylinder with a key. I tried the paperclip method and still no luck so I must be doing something wrong?

So I'm a little confused by the instructions.

Is this the correct procedure?

1. Insert large paper clip as far as it can go.
2. Insert key, turn it to the right to position one.
3. Pull out cylinder.

Thanks for your help,

Puma

[Wayne 962]

Originally Posted by Puma

1. Insert large paper clip as far as it can go.
2. Insert key, turn it to the right to position one.
3. Pull out cylinder.

You have it backwards - I have the steps outlined in the post above. I'll break it down:

1- begin by pulling out the rubber ignition switch surround

2- Turn the ignition switch to position 1 (ignition ON)

3- Insert a large paper clip into the release hole in the key cylinder

4- Push the paper clip in as far as possible, pull the key, and that should release the mechanism and allow you to pull out the assembly.

5- Finally, disconnect the small connector that attaches to the immobilizer induction coil (red arrow).

I just tried this on my 996, but I think my paperclip wasn't long enough, and I'm short on paper clips. When I wrote this article, I did it on the Boxster, it was pretty painless in general. Perhaps try a longer paperclip?

-Wayne

[Puma]

I tried it both ways and neither worked. So here's where I am now; I'm putting in the old version of the ignition that has the lock cylinder in it until I can make a trip to Dallas and pick up a new one (Porsche won't let me order this part without picking it up in person) I have the new assembly in the car with all the parts hooked up and when I turn the key there's no click of the solenoid. Is there something I have to reset with the immobilizer? Or is it something else I'm missing?

Your reply is greatly appreciated,

Puma

[Wayne 962]

Originally Posted by Puma

I tried it both ways and neither worked. So here's where I am now; I'm putting in the old version of the ignition that has the lock cylinder in it until I can make a trip to Dallas and pick up a new one (Porsche won't let me order this part without picking it up in person) I have the new assembly in the car with all the parts hooked up and when I turn the key there's no click of the solenoid. Is there something I have to reset with the immobilizer? Or is it something else I'm missing?

Your reply is greatly appreciated,

Puma

Hi there. Can you pls expand on this? I'm confused as to what exactly is going on, what you have replaced, what is new, and what is old?

thx,

Wayne

[Puma]

In a bizarre twist of fate I tried removing the cylinder one last time and it came out, smooth as butter. I have no explanation for this after the hours I spent on it.

Now I have the new assembly, cylinder and ignition electrical part in the car. Immobilizer is hooked up and when I turn the key I get nothing in the way of solenoid click. Power windows work so I've got power. What am I missing?

Thank you,

-Puma

[Puma]

Now I'm having a new set of issues. I installed all the new parts and not only does it not start I'm pretty sure that I installed the cylinder incorrectly (though it appears there's only one way it will go in with the black plastic guide into the groove on the ignition assembly) and the key will not turn to unlock the steering column which also means that I cannot get the assembly out of the steering column to reinstall it. The key doesn't turn in the cylinder properly at all, feels very weak if you know what I mean, there's no measurable positions to it and column is locked. I'm trying to turn the mechanism at the other end of the assembly in hopes that it will let go of the steering column so I can get that back out and start all over.

Banging my head on the wall.

[randy_k]

Originally Posted by Puma

Now I'm having a new set of issues. I installed all the new parts and not only does it not start I'm pretty sure that I installed the cylinder incorrectly (though it appears there's only one way it will go in with the black plastic guide into the groove on the ignition assembly) and the key will not turn to unlock the steering column which also means that I cannot get the assembly out of the steering column to reinstall it. The key doesn't turn in the cylinder properly at all, feels very weak if you know what I mean, there's no measurable positions to it and column is locked. I'm trying to turn the mechanism at the other end of the assembly in hopes that it will let go of the steering column so I can get that back out and start all over.

Banging my head on the wall.

Have you tried moving the steering wheel back and forth/ lock to lock while turning the key? Mine does this once in awhile when I have had the wheel turned when taking the key out. First time it happend I thought I had just bought a Porsche Paper wieght.

Randy

[Puma]

I've tried turning the wheel back and forth and changing the gears and depressing the pedals (who knows what will work?)

I got the key cylinder out of the new ignition assembly by taking the key apart and turning it with a pair of pliers. I know this sounds worse than it is. I discovered that an old key cylinder will not work with a redesigned ignition assembly. The new assembly has a spring mechanism in it that isn't depressed by the old lock so I have to go and get a new lock. I'm wondering if I have the right part? Could this be for a 996 and not a Boxster. The assembly pin that holds it in place will not let go and it is very frustrating. I tried turning the assemblies innards with a screwdriver hoping that would allow the pin to be depressed but the metal is soft and I think it could be damaged easily with the amount of force required to turn it.

[Wayne 962]

I don't think that you need a new lock, I think there is still something wrong, or perhaps something broken somewhere. The new ignition / steering wheel lockout assembly should be a drop-in replacement. I have this article that shows how to do it here: Pelican Technical Article: Boxster Ignition Switch Replacement - 986 / 987 (same link as above).

Can you post some pics of the misfit parts you're referring to?

-Wayne

[Puma]

I got everything back together and working. I believe that the issues were really caused by an excessive amount of gunk in the cylinder both in the release mechanism and the keyhole. Persistence and gentleness pay off with something like this. Thanks for your help with this issue. Boxster number two now has a brand new ignition, key cylinder and assembly. Thanks Wayne.

[Wayne 962]

Great, glad to hear it worked out! A lot of these cylinders get clogged due to lint and fuzz and other crap that gets on your keys while they are in your pocket and also exposed to the outside world. Almost every lock cylinder I've taken apart is just black with gunk on the inside.

-Wayne

[suprtran]

I followed the instructions and used a paperclip to remove the ignition key assembly as shown in the picture above:
Ignition cylinder, assembly and switch HELP!
My goal was only needing to replace the electrical ignition switch, so I later realized removing the key assembly wasn't necessary.

Now I cannot put the ignition key assembly back into place. Does putting it back require the use of the paperclip again?

[suprtran]

I managed to remove the key cylinder assembly using the paperclip method. But now, I cannot put the key cylinder assembly back into place!

I spent an hour fiddling with the assembly, trying both with and without the paperclip, to get the assembly back in place, but have had no luck.

Any advice?