Ignition/Start Switch & Lock Cylinder R & R 

By: Bernie Benz

On a PITA scale of 1 to 10, this job is at least a 12!

Application: Specifically 200Q 20V

Generally: all 44 chassis (100, 200, V8)

and 89 chassis (80, 90, CQ, Cab)

and any others having the lock cylinder in the dash to the right of the steering column.

Reference: Bentley 100, 200 Factory Repair Manual.

Other Bentley manuals as appropriate for other cars.

Symptoms: Electrical and /or mechanical failure.

Switch: START return spring anchor point cracks / breaks neck of plastic switch housing, causing the Lock Cylinder drive tab break off.

Lock Cylinder: Pot metal switch rotator tab on back of cylinder breaks off. Switch will not follow key position.

If either condition exists both the switch and the lock cylinder tab should be replaced as follows:

This procedure simplifies and clarifies the Bentley instructions in that the steering wheel and steering column switches need not be removed and the air bag system is not involved.

Special tools and parts required.

Torx tamper proof T30 bit. $3.50 shipped, eBay.

4A0 905 848B Ignition Switch. eBay, $3.50 ch / $10. ger

893 905 855A Ignition Lock Cylinder. eBay, $27. or

803 54016 500 Ignition lock cylinder. eBay, $29. Either OK

1. Remove the top half of the steering column plastic cover
2. Remove the Instrument Cluster. Bentley 70.16
3. Remove the Storage Tray (DS kick panel) B 70.16
4. Remove the small dash trim piece with vent left of the steering column and free up but don’t remove the right side dash trim piece surrounding the Lock Cylinder.
5. Need to improve visibility and access to the underside of the Ignition Switch and the Steering Lock Housing. The harness crossing under this area has a stiff black plastic protective casing around it which I removed, cut it away

with tin snips between the steering column and the center console.

6. Remove the harness connector from the back of the ignition switch. No holding clips, just prys off.

Don’t try to remove the ignition switch from the Steering Lock Housing in situ! It will come out much easier with and  still attached to the Steering Lock Housing.

7. Remove the felt sticky tape rapped around the Steering Lock Housing attachment area to the Column Tube for access to the Torx attachment bolt.
8. Remove the tamper proof T30 Torx bolt holding the Steering Lock Housing to the Column Tube. B 48.4
9. Remove the DS foot well air duct. B 48.6
10. Remove the two lock nuts attaching the Steering Column to the Flange Tube on the Rack Input Shaft, using a back up adjustable wrench on the lower flat portion of the Flange Tube. B 48.2 and B 48.4 (Tight nuts!) Turn the steering wheel 1⁄2 turn to access the second nut and turn back to straight to keep the Steering Column orientation to the rack.
11. Remove the 8 Column Tube mounting bolts, 4 on top and 4 on the left side. (What overkill!)
12. Move the Steering Column shaft flange to the left and up, off its mating flange on the rack input while pushing the steering wheel and the Column Tube down, toward the fire wall about an inch.
13. Now the Steering Lock Housing with Ignition Switch attached, will have enough tortured room to be pulled free to the right from the Column Tube and wiggled and twisted around and down, and pulling the harness out of the way, it will come out!!! Having fun yet?

14. With the Steering Lock Housing out and in hand, remove the Ignition Switch from the back of the Housing and drill the Lock Cylinder release access hole in the Steering Lock Housing per B 48.6.
15. Remove the Lock Cylinder from the Steering Lock Housing by pushing in thru the hole on the retaining spring while pushing the lock cylinder out trom the back. B 48.7
16. If you wish to eliminate the Steering Shaft Lock feature, remove the swaged in cover piece on the side of the Steering Lock Housing and drive the the lock shaft out of the housing thru this opening.
17. If you use the new lock cylinder you will also have to use the new ignition keys that come with it, thus having two different keys for the car. Or, you can remove the tail piece with the good Ignition Switch operating tang from the

new lock cylinder and install it on your old Lock Cylinder.

This tail piece is held to the back of the cylinder with a 1/16” roll pin, drive it out. Relube the old Lock Cylinder with powdered graphite or MoS2.