Can't get the steering/ignition lock assembly out, w123
 

Not this cowboy's best day at DIY ranch. Working on my '85 300d.

I had removed my keyswitch a while back when I was having issues with a sticky key... only to find the keyswitch was fine, it was the actual locking mechanism sticking. Finally got to it today.

Followed the DIY from the Diesel Giant site, more or less -- my lock was not jammed, which his instructions presuppose. Also looked at the FSM.

Got to the point where I had the steering column dropped and the clamp holding the lock assembly loosened off, but the lock assembly would not come out because the lock pin (the one he grinds off in the DIY) was not retracting properly. After trying to drive it back in, I gave up and ground it down.

But I still could not get the damn lock assembly out after I ground off the pin. I was able to get it to twist to the right (toward the firewall) in the tube, but not to the left at all - and I if I understood the DIY correctly he says it has to turn left to slide out.

I finally gave up and buttoned everything back up, as I was running out of daylight and I need the car for tomorrow.

So I still have the iffy lock assembly in there, though now with no steering lock. Works nice for now. Reinstalled a keyswitch.

Any advice? Have I missed something?

You have managed to come up with a problem that I have not read of anyone else having.
I am not sure what is holding yours in.

I removed and installed My new one without lowereing the Steering Colum. But, there is slight differences in the Cars year to year so that I may have more room then you do.

Diesel911, this has been the theme of the whole battle with the ignition on this car. I had two threads where I talked about not being able to get the tumbler to release. In the end it turned out it was releasing, but the sleeve was jammed on on the lock mechanism so nothing was happening when I released it. Someone before me had buggered the threads really badly.

I have mitts for hands and really couldn't get much leverage on the lock mechanism to work it out. I have a neighbour who wrenches and is a slightly built guy. I will pull it apart next week and see if he can get in there and twist it out. Have to call on him anyway as I for the life of me could not get the speedo cable put back on, not with my hands and wrists pushing the cluster out and messing up the angle.

When in doubt... grind again
 

Just to close the thread... I realized a couple of days later, when BOOM my steering lock suddenly started functioning again - which would be impossible, had I ground the lock pin down properly - that I hadn't been aggressive enough with the Dremel.

Hit it again today with a fresh grinder bit, and the lock assembly popped free eventually. Still not a fun job to change the lock assembly if you have large hands, but it's done. Electrical switch also replaced.

Just a note for the future, I have found it easiest to just remove the entire steering column with the lock assembly intact, and work on it outside the car. This is providing you can turn the key to the first position to release the wiring connection. Trying to remove the locking mechanism with the column still in the car (even unbolted), is much harder to do than just removing the entire column. It is also easier to damage the dash by twisting the lock mechanism while trying to remove it. It only takes about 10 minutes to remove it completely. I did it twice (out and in TWICE) in about an hour the other day. I replaced the mech with a good used one (so I thought), and had to take it out to replace it with another one. You will see what I mean if you do it this way, that it is faster and easier than trying to work on it with the column in the car.....Rich

If by bad luck I have to do it again on this car, I will probably do that. I have a completely uncracked blue dash and the idea of yanking on it to pull the area around the key switch cutout clear of the lock assembly when dropping the column did not go over well with me (more so because I had to do it multiple times when fighting with the thing).

Thanks

If I could post a video (of how fast and easy it is) I would, but having no video equipment or Youtube posting savvy, I will leave that up to someone else. I just know now that it is actually easier than I had originally thought to remove the entire column. And needless to say, it is very easy to remove/work on the locking mechanism with the column on the bench or in your hands.