I've got an ignition switch that doesn't always turn. Most of the time it's fine, but at times you put the key in and it won't turn at all. It's like it's locked up. It works fine in the doors so I assume it's not the key. And it's not the steering interlock. Any ideas?? If it's the ignition switch, does anybody have any pointers on how to change it? Any special tools required? Any help would be great!!

You are walking on thin ice with the key not turning and hanging up. If it jams or lock where it won`t turn, it will have to be drilled out, not a fun job.

www.dieselgiant.com has a pictorial on the ignition lock, and how to grind it out.

It is probably the lock tumbler that is bad. this is a dealer item. drive down there show them proof of ownership, and you will get a new lock and key in a day or so.
You can get aftermarket tumblers with a key, but if you loose the key, you are SOL.

to remove the tumbler, insert key, turn to position #1. use a paper clip (straighten it out) and stick it in the hole in the tumbler. this will release the locking pin. then unscrew the black collar, and the whole assembly will come out.

I replaced mine couple yrs back but still was having problems had to shake the wheel to get the key to turn.

Finally just replaced the whole thing. comes with ignition switch, vacuum shutoff valve and the steering lock assy. did this about 6 weeks ago.

Now smooth as butter.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

You can save the lock by removing it, and wash it thoroughly with dish washing liquid and hot water. Use the key and move it in and out while washing in a pan. Look for all the shavings and gunk that gets washed out and when there are no more junk coming out. shake it dry and DO NOT lube it with anything- you're done. The key should now work nice and smooth every time if not worn too much..

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked