1991 GTi I am trying to replace a faulty ignition switch. I have reved the steeing wheel and the combination switches. I ahve removed the allen cap screw holding the lock to the column. I have also removed the lock barrel. The book states that I have to slide the lock off the column. Some versions refer to prising he lcok washer from the inner column and reving the spring. I can identify the Bearing and Spring but no lockwasher. The spring seems to be held in place by a bush splined on to the column. A puller slips of the collar before the bush moves. How do I get the lock off and thus the switch out? Is it possible to drop the switch out without removing the lock?
Well, I just did the same a couple of weeks ago, so... What the (Haynes?) book doesn't tell you is that there are (at least) 2 type of fitting at the top of the column. I've seen both types - I removed the switch from one with the splined-on bush and fitted it to one with the lock washer. What I did was... Removed the splined-on bush with a small 3 legged puller, although doing quite a bit of damage to the bush in the process, due to insufficient lip on the bush - it kept slipping off (as you found)and burring the bush's edge. I wasn't bothered about this as I wasn't reusing it, butyou might try andfit a Jubilee clip around the legs of the puller. If all else fails, buy a new bush and grind the old one off is what I'd do. Once the bush is off, it releases pressure on the spring - there's no lock washer. With the older fitting (the lock washer), I couldn't shift the washer either, so gave up on the top end - removed the clamp bolt from the bottom universal and pulled the inner column out. Not my idea but I have a friend with lots of Mk 2 knowledge! I could have forcibly removed the lock washer but was in the middle of nowhere on a Sunday with no spare washer. This gives you enough room to remove the switch.
i find it easier to undo column from UJ, and remove it all as one....then bend the end of a small screwdriver and you can get to the screw holding the switch in.
Fixed it by removing the bolt from the bottom UJ. Simple. If you did want to pull the bush off you can now at least put the whole lot in a press and do the job properly. Did get a suggestion to put mole grips around the bush and then pull on that
Waking up a very old subject, I have the problem that the lock barrel has failed in that it takes about 5 minutes fiddling with the key before it decides to turn. I have the splined on bush which is proving very stubborn. Is it possible to remove just the lock barrel without the rest of the steering lock? Is it the Haynes method of drilling a 3mm hole to press a spring?
yep drill the hole and lock barrel comes out. you may even be able to do this with everythign still on the car but I've not tried. as previously mentioned if not just pull the column off with lock housing attached then attack it with a drill
Thanks John, OK, I am going to attempt to drill the hole with it still in place, otherwise I need to drill out the break-off bolts, which look a bit awkward to get to.
no need to drill the shear bolts, as per previous advice if you undo the allen bolt underneath, remove the bolt at the bottom of the column holding the universal joint on you can pull the column with switch housing out of the column tube
