How to change ignition switch?

Hi albert arthur,

Sorry to say that you need to turn the key to start position before the cylinder can be removed.

Check for any key bits still left inside key cylinder that is getting ijn the way. You might have to consider putting back the broken pieces to turn the key.

LOCK CYLINDER (FUNCTIONAL)
Removal & Installation
1. Disconnect negative battery cable. Position steering wheel half way between upper and lower tilt stops. Remove steering wheel. Roll back shift lever seal from upper and lower steering column trim covers. Remove tilt wheel lever. Remove lower steering column trim cover. Remove screws retaining upper trim cover. Lift trim cover to gain access to lock cylinder access hole.
2. Hold ignition switch in START position. Using a bent tip awl, push on lock cylinder retaining pin. Release ignition switch to RUN position, and pull lock cylinder set from lock module assembly. See Fig.
3. To install, insert key into lock cylinder and turn to RUN position. Ensure sector in lock module assembly is in RUN position. Insert lock cylinder into lock module. Align locking and positioning tabs with slots in lock module assembly, and press lock cylinder into position. To complete installation, reverse removal procedure.

Check out the diagrams (Below). Please let us know if you need anything else to get the problem fixed.

Does the key have a resistor on the side of it?

Continuity test of the ignition switch should be done, also check the switch hold down screws, there are two of them, they are 5/16th heads, see if it's loose.
Ignition & Turn/Hazard Switches 1. Turn ignition off. Disconnect Black 48-pin steering column harness-to-main harness connector under instrument panel. See wiring diagram in appropriate WIRING DIAGRAM article. 2. Connector terminals represented in wiring diagram (identified by a letter/number combination) match connector terminals of 48-pin connector illustrated. See Fig. 1 . 3. Connect one ohmmeter lead to power supply terminal of switch side of 48-pin connector. Connect other ohmmeter lead to appropriate terminal of 48-pin connector according to selected switch position. If continuity does not exist for selected switch position, problem is open in that circuit between 48-pin connector and switch, or faulty switch.

Recheck the ignition switch cylinder lock-could be offset

1. Disconnect the negative battery cable.
2. Lower the steering column.
3. Remove the washer head screw and the hexagon nut.
4. Disconnect the dimmer switch assembly from the rod.
5. Unfasten the dimmer and ignition switch mounting stud.
6. Seperate the ignition switch from the actuator rod.
7. Unplug the ignition switch electrical connection and remove the switch.

To install:

The new ignition switch will come in the OFF-LOCK position. Once the switch is assembled on the column, remove the plastic pin from the switch. If you are installing the old switch, make sure it is in the OFF-LOCK position.

8. Attach the switch to the actuator rod.
9. Move the switch slider to the extreme left position, then move the slider one detent right to the OFF-LOCK position. Install the dimmer switch mounting stud and tighten to 35 inch lbs. (4 Nm).
10. Attach the dimmer switch to the rod, then install the washer head screw and hexagon nut. Do not fully tighten at this time.
11. Place a 3 / 32 inch drill bit in the hole on the dimmer switch. Position the switch on the column and push against the rod to eliminate all lash.
12. Install the switch and tighten the screw and nut to 35 inch lbs. (4 Nm).
13. Attach the switch electrical connection.
14. Raise and attach the steering column.
15. Connect the negative battery cable and check for proper switch operation.

Running down three windows at once can be considered normal, so the circuit is designed to handle that. Even if a fuse did blow, it should not cause everything to be dead. A better suspect is to follow the smaller positive battery wire to the under-hood fuse box and be sure that connection is clean and tight. Most vehicles had an under-hood fuse box by 1991 so I am guessing yours does too. If not, I will have to dig up a wiring diagram.

Given the age of the vehicle, also follow the smaller negative battery wire to the body and be sure that one is tight and not rusty.

By the way, since power windows are considered a safety system, they are protected by an auto-resetting thermal circuit breaker. Once they cool down for up to a minute, they will reset, but if they have tripped numerous times they can develop arced contacts and prevent proper circuit operation. The windows are the only system that would be affected.

Could you take a picture of that "tar-like substance" and upload it to us please? It could be a sealant and it could also be a sign of something melted. Does anything smell melted? Do any wires or the plastic look melted?

The fuse box my colleague mentioned is usually close to the battery.

Are you saying everything is dead electrically? You might still have only a fuse box inside. Regardless, poke around on all of the fuses with a test light to see if there's 12 volts there. If there is, tell me exactly what works and what doesn't. In particular, does the "Battery" light on the dash turn on when you turn the ignition switch to "run".

A ignition switch absolutely can cause this. Also check the battery connections, some have 2 positive cables to the positive terminal and there is a lead spacer inbetween them that melts causing one cable to lose power. Id check that first. Also look for fusible links at firewall or at starter motor.(These are orange rubbery wires that can melt on the inside, lightly tug on them and see if they seperate. Im sure you will find your problem in these areas. Get back to us

The loose tilt part and the ignition rack are more then likely your problem. It does require a steering wheel puller and a lock plate tool and tilt pin tool. It can take a couple of hours or better to replace it. See with the tilt section loose the pushrod from the ignition lock cylinder to the ignition switch are not in sequence, that is why if you lift the wheel you put it in better alignment.