Need help with ignition housing problem-1981 300D!!
 

I just pulled the ignition switch housing out of the car. I had the ignition tumbler out already, but had a problem with the key spinning in circles without anything happening (cranking, etc). I noticed the spring loaded doodad at the back of the cylinder that the tumbler sits in was not exactly working correct, so I figure I need a new housing to make sure all is right. I got the housing out without completely destroying the dash, and now I need to get the electrical connector off of the back of the housing, but it's being a severe PITA for some reason. I don't know if it's because it's cold, or what, but I've grabbed it with channel locks, tried pushing on the 3 slots that look like the black plug may be clipped onto the aluminum housing wth, but nothing is moving. I'm getting maybe 3/32" on one side, but it's holding on like it's glued or something. What the hell am I doing wrong here? I mean, if I can't get it to pull out with a pair of channel locks gripping the plug, what does it take? All the posts I've read sounded like it's supposed to just come right out? I'd take pics, but my camera's broke. Help, Please! I'd like to get this thing out before dark if I can. thanks for any ideas.

There is a pin that needs to be depressed on the part that connects to the steering column. If you loosen the clamp, depress the pin and make sure the instrument cluster is out of the way; it should come out.

Thanks Craig, but that's not what I'm talking about. That's already done (even though it took me about 15 minutes to figure that out, and I nearly tore my dashboard up trying to get the housing off before I found it.) What I can't get off is the black electrical plug (rubber??) back (forward side) of the switch housing. The thing with all the wires coming out of it that feeds the ignition switch. I can't pull that thing out no matter how hard I pull. And I need to get it off before I can take the housing out of the car to check it or chuck it. But thanks for your reply.

I thought the electrical connector was just pressed onto the electrical switch so it could be pulled off. It's been a while, but I don't remember anything holding it in place.

yeah, I'm wondering if it's either so cold that it won't slide out, or maybe it's never been off, but it's got me stumped. I don't want to break anything. I'm thinking about spraying some silicone lube around the sides, or taking a blow dryer out and warming it up. Dusk is setting in, so I guess I'd better get out there and try something. I just don't want to crush anything in the plug by gripping it too hard with the pliers. Like I said to my wife, this kind of **** only seems to happen in the middle of winter or a rain storm.

Well, I went out and sprayed around the edges with silicone lube and tried heating it with a blow dryer just in case it was a hard rubber problem, but no luck. I even had my wife come out and we tried to pull the thing apart, me with the channel locks on the black connector and her on the housing. The only thing I can tell is that the pic on the dieselgiant DIY shows the "plug" sticking out of the end about an eighth of an inch or more, and mine is pushed in flush. there are 3 small slots about where it looks like the plug would 'seat' that may be holding the plug in, but I'm not having any luck trying to push them clear with a screwdriver while also trying to seperate the two parts, all the while being under the steering column (which I've loosened and lowered a few inches). MAN! My back-neck-shoulder-is killing me!!

Try getting ahold of Tom (t walgamuth), he just took one of these apart and might know a trick.

I think it's keyed to move off when the ignition is in a specific spot. The DG thread says in the second ignition position. If I understand what you're describing the "ears" are still engaged. See the pic from Fastlane parts.

http://catalog.peachparts.com/ShopByVehicle.epc?q=&yearid=1981@@1981&makeid=63@@MERCEDES+BENZ@@X&modelid=6188%3AED%7C10000132%3AMB C%7C1503@@300D&keyword=ignition@@ignition&catid=All@@All&subcatid=P%3A241656@@Ignition+Switch&applic ationid=W0133-1623898@@Ignition Switch&mode=PA

Can you turn/rotate the ignition to try to align the parts?

If the link to the pic doesn't work, there's also a pic in the DG how-to.

He has the tumbler out, he's trying to get the electrical connector off the back of the switch.

I have replaced 2 of these. I think you have to have the key in position #2 to be able to slide in the paper clip to remove the tumbler. It is also the same position you need to be in to remove the plug off the rear of the steering lock assembly. You can not just simply pull the plug off w/o using the paper clip.

Charlie

Understood.

But I think the electrical connector on the back has a keyway that needs to be aligned so it can slide off. I don't recall having to align it in my car when I pulled it, but then again, my key wasn't spinning in circles before I tried.

Look at the pic and you'll see what I mean. Keyway, dogbone, butterfly. There's something non-circular in there.

Since the OP has tried force, heat and lube, maybe a little finesse by gradually rotating the switch with through the place where the tumbler was may help.http://img.eautopartscatalog.com/hir...300&height=300

remove switch
 

The switch has to be in the correct position in order to remove the electrical plug. I believe it is the same position needed to remove the tumbler. Just turn the switch like with a screwdriver one position at a time and try it until it releases. It's locked in the same as the tumbler.
been there done that on my 240D.
Jon J
81 240D 275000 mi

Ohhh.... That makes a lot of sense. Once I got the tumbler out to check it, I didn't even consider that the inside of the switch housing would need to be in a particular place. I can turn it with a screwdriver. It seems the little spring loaded "catch" that contacts the key end that protrudes through the tumbler is a little weak, as in sometimes it springs back, sometimes it doesn't. (I've had to reach in there and physically use a pick and get it to return to an extended position a few times).

So, with this in mind, I'll go out and rotate the housing's insides until I get the right spot, and pull it off. Boy, that's a relief to know there's a trick to it! Wish my camera hadn't shot craps, I'd take some pics and post them so others down the line would be able to see what's what with this problem. Reminds me of when I was changing out my fan belts last summer, and I nearly beat the AC to death until I found out that I there was a third bolt that I hadn't been aware of. Thanks, everybody. I think I'll eat breakfast, take some painkillers and go to work on it. That sunny day outside, even though it's 24* here, looks a lot better now that I've read these replies. Sorry if I was unclear in describing the problem yesterday. I was hurtin' so bad, I could barely think. Much obliged to you all!

I didn't know that. I guess I just left mine in the correct position when I removed the tumbler so the connector came off with no trouble.

Me, neither! Since mine was turning completely around, (which I now think may be because of the fore-mentioned "doodad" that I had to pick out of the housing), I was experimenting with the housing's inner moving parts to see if that was the problem. As mad as I was about the one year old, $17 tumbler being bad already (it's not), I'm even more bummed about the $100 housing or being the culprit. On the other hand, it's not out yet, so stay tuned.