Re: Sticky Ignition Key Fix for all Crossfires 2004 thru 2006
I recently did two of these and I found the instructions to be fantastic, and very helpful. I do have a couple of ideas to add that could help out future people with this endeavor.
Tools: You do need a box end or open end 10mm wrench to undo the screw on the band clamp that lockers in the ignition module.
A regular Phillips head screwdriver works for most screws, but you either need a stubby or offset screwdriver for the two screws holding the cover under the steering column (in #4). A power drill really just gets in the way, so don't bother.
A small gooseneck pliers to remove the tumbler barrel (10) and also to remove the main electric harness connector (13). I will explain below.
A milk crate! This is fantastic for any under dash procedures, as they are about the same height as the rocker panels of most cars. Sitting on it, and placing it next to the rocker panel to make a bench is so much better than kneeling outside the car and breaking your back to lean under the dashboard. I put the cushions form the patio furniture on the milk crate and the rocker panel too, and this makes a very comfortable bench to lay on to see under the dashboard. Try it!
I ran into two issues. First, getting my big hands behind the ignition module to push the main electric harness connector (13) off of the ignition module. I found the small gooseneck wrench fit under the dash, and fit over the verticals flange that is on the back of the main electric harness connector (13). I could then just wiggle the handles while pushing back and it came right off. Also the small gooseneck wrench is better for removing the tumbler barrel than bulky vise grips.
Second, after using a Flathead screwdriver and hammer to open the pin hatch (lengthwise) and then close it too (it helps to have a table vise and some blocks of wood to hold the ignition module steady during this process, or a friend with vise grips). I found that the repaired ignition module did not want to slide back into the collar, and I found no mention of this anywhere in the internets. Oddly on the same day someone else here also had the same problem, so I wasn't going crazy, the solution was a bit of white lithium grease, or dielectric grease, or he used WD-40 on the barrel that slides into the steering column yoke. Just a little works, perhaps as these are aging this is becoming a new problem.
That's my Dos Centavos on this subject, and my thanks to all the authors of this thread for saving me and us so much money and angst by supplying this great tutorial.