993 Ignition tumbler removal

[DamonsCarrera]

So, I have a key that is busted off in the ignition (don't ask how that happened.)

Is getting the tumbler out as simple as drilling out the two shear bolts and pulling the tumbler out from the front?

Or do I have to R&R the entire steering lock assembly?

Anyone have any advice?

-Damon

[prschmn]

You'll have to remove the whole assembly to do it.
But it's the same as older cars in that there is a small pin which has to be removed.
If you search the 911 forum you'll find pictures, etc guiding you through it.

[DamonsCarrera]

Mark, thanks.

Is the pin hardened? Drill it out or pull it out?

-Damon

[prschmn]

Look here. Should get you going.

Ignition switch - inside to fix START lockout

[DamonsCarrera]

Great, thank you!

[DamonsCarrera]

An update in the ongoing saga of rebuilding a 993 ignition lock....

There are three shear bolts that must be removed to get the steering lock assembly out.

The first two of these bolts, the ones at the front of the lock under the decorative 'rosette', come out best by drilling the heads off. I tried some other ways suggested by various internet sources (tapping the bolts loose by using a hammer and punch, grinding a slot in the head and unscrewing with a screwdriver). These methods didn't work for me. The bolts have locking compound on the threads and that makes turning the bolts very difficult, or rather impossible.

The third bolt is different from the first two. PN 999.219.024.02, it is really a set screw rather than a bolt, since the head shears off during installation. It has locking compound on the threads also.



Once that set screw is installed and the head shears off there is just pretty much a flat surface left.



The Bentley manual says "Loosen fastener holding steering column lock to outer tube" but loosening a headless shear screw with locking compound on the threads is going to be quite a job.



So I think I have to drill this shear screw out. But, there is no good access for a drill bit from under the dash unless I drill a hole in the bottom of the dashboard rail as shown in the photo by the white circle.



And the hardest part of this is, I think I'm going to have to drill out the entire shear screw down straight past the threads in order to get the steering lock assembly free. And hope I don't damage the threads in the process.

Has anybody out there done this before? Is this the best or only way?

The older cars have a much easier nut and screw arrangement, but I guess they had to get fancy with the 993s. :^(

I welcome any ideas.

[john walker's workshop]

How about using two sharp pins, at the top and bottom of the broken key and lever it out?

[964TargaC2]

I saw a locksmith use a vacuum to remove a broken key, I dont know it he had some sort of special attachment on it

[prschmn]

Yup it's a pain. I've drilled the lower hole and then used a left hand drill for the bolt.
Unless as JW said you can manage to get the broken key out.