Ignition Switch Replacement

Introduction

Cracked ignition switches are a known cause of starting problems on 944s and the 924s. Closer inspection will often reveal a visible crack in the switch body. The procedure below was documented on a 1987 924s fitted with an aftermarket (non-stock) steering wheel; steering wheel removal steps will differ for a stock wheel (see BODY-25, Steering Wheel Removal and Installation). The remainder of the procedure applies to both.

Note: With any non-stock steering wheel, the removal method varies. Always mark the steering column shaft and wheel/adapter orientation before removing — use a scribe or contrasting paint pen. Lay removed parts out in order as you disassemble; small screws are easily misplaced.

Tools

• Phillips screwdriver #1 (smallest standard size)
• Metric Allen wrench set
• Various-sized flat-tip screwdrivers
• Small pry bar
• Hammer
• Brass drift or large deep-dish socket
• Small scribe or marking tool for indexing wheel to column
• Steering wheel puller (may be required)
• Good shop light

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Procedure

1. Confirm the steering wheel is centered and the wheels are pointing straight ahead before removing the wheel.

2. Non-stock wheel (aftermarket adapter): Remove the six Allen bolts from the center of the wheel. See BODY-25 for stock wheel removal.

3. Disconnect the wires for the horn (method varies by wheel type).

4. Non-stock wheel: Remove the rubber boot from around the adapter/crush zone.

5. Before removing the wheel, verify the alignment mark for "TOP" if present. Confirm the wheel is centered.

6. Remove the center nut. Use a large screwdriver through the adapter bracket to hold it steady while removing the nut with a socket. Remove the nut and washer but leave the wheel/adapter in place for now.

7. Scribe or mark the steering shaft and adapter (or wheel) to preserve their relative orientation.

8. Slide the steering wheel or adapter off the steering column.

9. With the wheel removed, the stalk switches are now exposed. Remove the three flat-head screws on top of the stalks.

10. With the screws removed, the stalks will be loose. Remove the plastic housing around the stalks — it splits longitudinally and is held by two screws from below. (Removing the housing is easier with the wheel already off and the stalks loose.)

    Note that the two lower screws are different sizes.

11. Carefully slide the stalk switches off the column. There are wires connected to the switches — work them out carefully from underneath while gently pulling the switches forward. The two stalk assemblies can separate from each other during removal; if they do, continue guiding the wires out and reassemble the stalks once removed.

Caution: Three small screw hole bosses remain on the column after stalk removal. Do not pry or hang anything from these — they break easily and require replacing the entire piece.

12. Remove the plastic spacer collar from around the steering column. Pry gently in the slots at the bottom with a flat-tip screwdriver until the collar moves, then switch to a wider pry bar and carefully work it off. Do not pry on or near the three small screw hole bosses.

13. Remove the Allen head bolt on the left side of the column. This bolt is accessed through a hole in the bottom of the dash.

14. With the Allen bolt removed, the assembly holding the ignition switch slides out of the column. The switch assembly has several wires attached at the back.

15. Unplug the wires from the back of the ignition switch. Flip the assembly over and locate the small Phillips screw on the back. Remove this screw and the switch slides out.

16. Slide the switch out of the assembly.

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Installation Notes

• Apply a light coat of grease to the end of the new switch where the ignition lock tang engages — this area sees significant wear.

• When reinstalling the bracket assembly, pack the column bearings with fresh grease.

• The plastic spacer ring/collar may have developed burrs during removal. Lightly sand or file them before reinstalling. Apply a light coat of grease inside the collar to aid installation. Do not use a hammer and screwdriver to tap it in place — this will crack the plastic. Instead, use a large deep socket against the collar and tap alternately from side to side.

• When reinstalling the plastic trim pieces around the stalks, install with the stalk switches in place but not yet screwed down. This allows some play when fitting the trim. Press the top trim piece down and back until it snaps into position.