Cougar/XR7 V8-4.6L VIN W (1997)
Ignition Switch Lock Cylinder: Service and Repair
Cylinder Inoperative
NOTE: The following procedure applies to vehicles in which the ignition switch lock cylinder is inoperative and the ignition switch lock cylinder
cannot be rotated due to a lost or broken ignition switch lock cylinder key, unknown key number or a lock cylinder cap that has been damaged or broken.
REMOVAL
1. Disconnect battery ground cable.
2. Remove steering wheel.
3. Through the access hole in the lower shroud, use a small pilot punch to center punch the retaining pin and then drill out with 1/8 inch diameter
drill.
4. Using channel lock pliers or vise grip pliers, twist lock cylinder cap until it separates from the ignition switch lock cylinder.
NOTE: It may be helpful to drill a small pilot hole prior to using a 3/8 inch diameter drill.
5. Using a 3/8-inch diameter drill, drill down middle of ignition switch lock cylinder key slot approximately 44 mm (1-3/4 inch) until ignition switch
lock cylinder breaks loose from breakaway base of lock cylinder. Remove lock cylinder and drill shavings from lock cylinder housing.
6. Remove retainer, washer, ignition switch lock cylinder and actuator. Thoroughly clean all drill shavings and other foreign materials from casting.
7. Carefully inspect ignition switch lock cylinder housing for damage from the above operation. If damage is apparent, housing must be replaced.
INSTALLATION
1. Replace lock cylinder housing if damaged.
2. Position lock drive gear in base of ignition switch lock cylinder housing in the same position as that noted during removal procedure. The position
of lock drive gear is correct if last tooth on drive gear is meshed with last tooth on rack.
3. Position bearing retainer in ignition switch lock cylinder housing. Insert tip of a screwdriver into double-D slot of bearing and then rotate 90°.
4. Press blue plastic bearing retainer into lock cylinder housing. Make sure retainer is in its original position.
5. Line up flats of drive gear with flats of washer by pulling down on the column lock actuator.
6. Install ignition switch lock cylinder.
7. Install steering wheel.
8. Connect battery ground cable.
9. Check for proper start in PARK and NEUTRAL. Also, make sure start circuit cannot be actuated in DRIVE or REVERSE positions and the
column is locked in LOCK position.
