I have read a couple threads on removing, replacing the ignition. Is this a death sentence for the ignition or is there an alternate? Like some wd or such? I have not had any trouble until my wife drove it several times. Is it possible she jammed something with her "delicate" touch? It will turn to position 1 but not to the start psition.

I got a chance to work on ignition this morning. I am able to insert the 1.5 millimeter allen wrench in the slot approximately a inch and a half. the collar still won't come off. what am I doing wrong, should I feel something in there? do I need to put pressure on it?

I find a small straight slotted jeweler's screwdriver to be a better tool to push down the dog because of it's wedge shaped end.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

How much pressure are we talking about? I had to take a break because the tips of my fingers are raw.

Not a lot of pressure but I found no success with a straightened paper clip. Anything with a square end just pushes against the dog without rising up over it and pressing it down.

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

okay thanks I'll see what I've got a little bag of tricks.

Ignition Cylinder Tumbler replacement; mixed diesel/gas

Caveman time..

You need three things:
#1. Steering must turn.
#2. Ignition electrical switch must turn on/off.
#3. No shutoff vacuum leak = mark the hose positions and insert a golf T in each.

I am not going to detail cluster removal or dismounting the column.
IMO there is no reason to remove the steering wheel, having done this operation more often than I want to remember..

Break the three aluminum ear tabs, the switch screws go into these = once broken the switch falls out.


Loosen the clamp.
Here is the locking pin you need to beat to death = pound it in far enough and the lock slides out of the column.




This person drilled the hardened pin.
W126 300SD ignition steering lock failure lost keys

Ignition lock cylinder, not the tumbler.....

Ignition/Steering Lock snafu




Ignition Switch problem 1981 300 SD.




removing ignition switch






.

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1985 300SD
1983 300D
1984 190D
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Ok, I think I am confused. Does the wire remove the tumbler or the collar around the tumbler? I had to take a day off as my finger tips were un happy.

Actually both are true. The same part inside the lock the Lock Tumbler in place rises into a recess in the Sleeve and locks that in place.

Also on mine when I put the Sleeve back on I found that if I screwed the Sleeve all the way down the recess was not in the correct spot and I had to back it out to line that spot up.

Comment on the use of a Paper Clip. A Paper Clip is not strong enough if you try to stick the long lenth of it in; it will bend. If you get a Needle Nosed Pleirs and grab the Wire about 1/4" from the Tumbler you can shove the 1/4" in and take another 1/4" and keep doing that till it stops.

I could not find the larger sized Paper Clop and used some Wire I had on a Spool using the same Method.

Attached Thumbnails

 

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84 300D, 82 Volvo 244Gl Diesel

Assuming the switch will turn to the proper position a piece of wire or a paper clip will work, but I would file a point on the end to guide it. I used a large canvas sewing needle. Point helped guide pin in.

I happened to have a new lock cylinder in my desk. I tried a paper clip to reease. Only the small size clip would fit in and it really was too bendy. Need something stiffer.

From some pictures on-line it seems that the release hole is not always the same size.

__________________
Graham
85 300D,72 350SL, 98 E320, Outback 2.5

I dont have the service manual open but as I remember you need to file a u-shaped tool out of 3/32 welding rod or smaller with a specific angle on both tips: if you dont follow the instructions you can push all day long and nothing will happen, but if you follow the manual the ignition pops out easily. So if your fingers are raw, you arent on the right track. Once you see it out it all makes sense.

I am not sure on his Model. On mine you only need to insert the Tool/Wire into one hole.

About 2 or 3 weeks ago someone posted a later model Mercedes and on that one you need to insert the Tool into 2 Holes.
I have that particular 2 end Tool that I got when I bought a Lot of Mercedes Tools on Ebay. It is a thick U shaped bent wire with kind of hypodermic needle poits gorund on the ends.
But, that same Tool would not work on mine unless I cut it so I only had one Wire.

I am not sure which one He needs but if he has 2 Notches in His Tumbler Face it is He would likely need to stick something down both Holes when they line up.

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84 300D, 82 Volvo 244Gl Diesel

I seem to only have one hole. I will look again. I ended up grinding an angle on the end of the allen wrench. I only fooled with a little while after that.
Just so I am clear,
I can turn the key to the first position to the point the radio comes on but no glow plugs. I turn it back and align the slot. I can then insert the allen about an inch and a half. This is where I am having the trouble. The collar will turn about 1/6" cw/ccw but no further. I dont seem to feel anything in there.
On another note after all the jiggling and fiddling I was able to get it started and move it out of the middle of the driveway and up to the garage. Then the next try no love!

I can't remember the proper position but what you wrote does not seem correct to me. Seems to me it should turn at least one more position.

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

There's a picture on here:

http://dieselgiant.com/repairignitionlock.htm

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13