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I had a similiar problem with my 85 300D. It took a considerable amount of jiggling of the key to get the steering lock to disengage so I could turn the key. I dreaded hearing the steering wheel lock clicking sound when I got out of the car because I knew I would have to fight it when I got back into the car. So I followed the advice of this forum and had the tumbler replaced. This helped a lot. However there were times when I still had problems with the ignition switch, it just wasn't as bad before. (I had this done at the dealer and I think they charged me $110 for it). If you had the magic touch like I did, I could start it. My wife on the other hand did not have my fine skills and refused to drive the car until I fixed it.
I took the lock assembly of the steering column out of the dash. It appears that even with a fresh lock the stearing wheel lock assembly must have worn and it was not releasing like it was suppose to. I found away to defeat the steering lock. Although my steering wheel no longer locks, the key assembly turns as smooth as butter now.
This is what I did. The entire assembly needs to be removed from the steering column. There is a shaft that fits into a socket on the column. Within this shaft is another shaft that is spring loaded. It is the inner shaft that can be pushed in with the finger or if the key is turned the inner shaft is withdrawn. This allow the steering column to be unlocked. I drilled a whole across the outer shaft and placed a pin through it thereby not letting the innershaft to protrude out the end. (I made the pin out of a small piece of Oxy-Acy welding rod.) There is a small nub on the side of the shaft that aligns with a whole in the steering column socket. This is there to prevent the assembly from being removed if the key is not installed. This needs to be ground off smooth with dremel tool. The entire assembly is ready to re-install. The last thing to do is not to attach the two wire connector under the ignition switch that is for the key buzzer.
Yes, I know I have defeated a well engineered security system on my 300D. I still need a key, and yes the proper key, to start the engine. I just don't have the steering wheel locked anymore. In this operation only the switch assembly was modified, not the car itself. If I choose I can still by a complete replacement assembly if I wanted to. As of right not the key turns as smooth as butter I tell you.
TimK
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85' MB 300D Turbo
85' GMC Suburban 6.5L Diesel Turbo
2000 VW Beetle 1.9L TDI Diesel Turbo
67' Land Rover 2.5L Diesel - No turbo
So what do you do when it's so cold out your fuel gels? Smear some on toast and have another cup of coffee until it warms up outside.
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