I received a new key for my 82 300D direct from Germany through a local dealer. The original key is ripping through the plastic holder and not long for this world, but works fine in every place it is supposed to work. The new key will open the doors, but not work in the ignition. Local MB dealer "tech" says the ignition switch is worn out. The door has had as many operations as the ignition, so why isn't it worn out, too? I admit the new key looks totally different from the original one. The dealer took the VIN numbers as reference when the key was ordered. Suggestions??
Thanks in advance,
rsmcgee

You can try to "weather" the key. If you place your old key on top of the new one, you may notice that the old key is worn a bit here and there. Sometimes a few passes with a wire brush, or some gentle persuasion with a file (to round things off a bit), can fool the ignition switch into thinking that the old key being inserted. Just like people, cars tend to get a bit fickle as they get older. :D
-Larry

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03/83 300D 184k
07/73 280 (sold)
'88 other 168k

You can purchase a new plastic "end" for your current key. It's available at your MB dealer. Might be easier than trying to break in the new key...

Dale

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Dale
'82 300 TDT 330,000 km

You could also get a new plastic end for your existing key. They are available at your Mercedes dealer. The end actually is in two pieces and once they are clipped together over the metal key there is no way to separate them. This would save you "breaking in" the new key...

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Dale
'82 300 TDT 330,000 km

Sorry about the two posts. The first one was posted last night. It wasn't there this morning so I sent a second one. They both showed up at the same time. How does that happen??

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Dale
'82 300 TDT 330,000 km

Thanks for the good responses. The dealer wasn't adept enough to offer me the plastic cover, even though it was obvious what my problem was. Well, I have a good key for the doors in case I lock mine in the trunk (as I stupidly did in NYC one night when it was about 20 degrees out. The "A 1 Locksmith" finally admitted he couldn't sort out the security type key and I had to have the trunk lock drilled out! That only took about a year to sort out.)

tablerocknc
82 300D 172,000
Former owner 79 350 SEL, 249,000km

When I bought my '82 300D it only came with on key, so I went to the dealer and they made me a new master key (the old one was too worn to copy) and another key. It cost almost $50 Canadian with taxes. The two new keys still feel rough when inserting in the door lock or ignition compared to the old key. They work perfectly fine but even after using one of the new keys since spring it's still not very smooth. In response to your question I think Larry's idea is probably your best bet, but be careful not to damage the key.