Steering Column Repair: stuck ignition cylinder, torx bolts, chevy k1500


Question
I have a 1993 Chevy k1500 pickup. The ignition switch will turn to start the engine, but then sticks in the on position. I saw an answer from you on this same problem with a 97 chevy, but don't know if my setup is the same. Any help you can provide would be greatly appreciated. Thanks.

Answer

GM lock cyl
Hi Brent:
This is the beginning of a bad ignition lock cylinder.  When they fail, they begin to come apart inside the housing causing the binding problem.  When they actually blow up inside, you will not be able to turn it to all the positions anymore.  I suggest you replace it now while you can still turn it.  Here is a picture of how they come out as well as some instructions.  

The top cover on many GM vehicles is the tough part of this job, unless you know what you are looking for.  The most critical thing is not to break the red 4-way flasher button on the top of the column.  That's a $300 mistake.
First, remove the lower cover (2 20 torx screws).
Then, removed both 8mm inverted torx bolts holding the upper cover in place.  The one on the right side is hidden way up next to the lock cylinder...you will need a flashlight to see the head.  The one on the left is very visible on the lower left side of the cover.
Now, there are 2 ways to get the top cover off.  The first way is to force it off over the lock cylinder carefully avoiding the 4-way button.
The second and best way is to remove the airbag and steering wheel to release that ridge that goes under the wheel.  Once the wheel is off and the bolts are out, the only thing left is the lock cylinder.  You can force the cover over the lock cylinder and gently break off the ridge behind it, or you can release the lock cylinder, remove it and the cover comes off easily.  Releasing the lock cylinder can be challenging as well.
I'll enclose a picture for you, but the release pin is a small 1/8 hole in the top of the housing about 3" in from the black bezel.  You will not be able to access it easily because the cover is blocking it.  You will need a long right angle probe to reach in and depress the pin.  However, you must rotate the lock to the 'start' position in order for the pin to be in position to be released.  The lock will be very hard to turn as the cover will be rubbing it and you won't have much room to both see and do what you need to do under the cover.  You will also need to disconnect the battery so you do not repeatedly engage the starter while trying to hit this pin.  Once the pin is pressed properly, the lock will come out about 1/2 inch.  Then release the lock to the 'run' position and slide it straight out.
I hope you understand all this

Good luck
Doug