Question'93 Ford Aerostar ext. van, Eddie Bauer edition. I've
had problems with accessories wired through
steering column i.e. gear shift indicator broken, no
horn, airbag light blinks constantly, cruise control not
working. Today the key jammed and won't budge,
and the wheel is stuck and won't release. I had to
leave it in a parking lot 'cuz it was after 9pm. What
do I do? Will replacing the ignition switch fix the
problems or is it something else? I know the wheel
being stuck affects the ability for the key to turn, but
not sure exactly how. Do I call a mobile mechanic,
tow it to Pepboys or would AAA be able to pull a
rabbit out of their hat? I'm tired of being ripped off
by mechanics who diagnose & fix a problem, but
what they fixed isn't the REAL, and underlying issue.
I've had transmission problems for a long time, but
there is nothing I can do about it unless I can shell
out $2100 for a new one. The transmission shop
owner (who happened to own an Aerostar himself,
and just replaced his tranny) told me since it would
cost more to fix it than the vehicle was worth, "just
baby it until it dies!) Well it's been 10 yrs and other
than shifting a little rough, the tranny is fine. It's all
the other electrical problems stemming from the
column that are financially killing me. If it were your
vehicle, what would you do? And what am I looking
at cost wise to fix it? I live in Escondido, CA.
Answer
ford lock cyl release
If the lock cylinder will not turn because of the wheels being turned too far, the easiest way to release the pressure is to simply jack up the front wheels, and then gently rotate the steering wheel while trying to turn the key. If that doesn't work, then we will have to force and break the lock out without damaging the housing. Once this is done you will need a new lock cylinder & keys to install because we are going to break the old lock into 2 pieces.
This takes a lot of effort but can be done. Once you remove the lower cover from the steering column, you will be able to see the small 3/16 hole on the bottom side of the lock cylinder housing. Inside that hole is the release pin for the lock cylinder. The problem is that the release pin will only go in once the key is in the "on" position. You will have to take a 1/8 punch and drive that pin into the lock cylinder, breaking both the lock cylinder and a locking tab deeper inside the lock (one you can't see yet).
When you do this correctly and successfully, the head of the lock will fly off first and then the lock itself will actually pop out about 1/2-3/4 inch. You can then slide the rest of it all the way out (sometimes you need to help pry it out).
Now, looking inside the hole you will see the tip of the lock cylinder still stuck inside the gear. Once again, this little piece and the ignition have to be turned to the "on" position before it will come out. You can accomplish this by pushing the ignition rack gear itself with an angle probe towards the dashboard until the dash & ignition lights up. If you push it too far, the truck may actually start, so be careful.
Once the pieces are out, install the new lock cylinder (in the "on" position), reassemble the cover and you should be all set.
Here is a web page to help you understand the inside of your column
and how to put the lock back together,
http://www.stolenandrecovered.com/howto/fordupper.php#g1
Good Luck
Doug
