Broken key in the ignition column lock/barrel

[Grogers]

Hi all

So, came home after a nice day out in the old Lotus (Elan S2 1994). Carefully backed the car into the garage and turned off the engine hearing a louder than normal click from the ignition lock. When I removed the key it was missing 15mm off the end. This end piece which as clearly broken off is still in the barrel.

I have tried replacing the key in the lock hoping that the two pieces would still marry up and allow me to turn the lock but sadly no, the key will now not quite fully insert and the lock will not turn.

I have contacted six auto locksmiths today, however, they are not interested in even coming to look at trying the get the broken piece out of the lock.

Can anyone let me know where to source a compatible column lock from and how easy/hard it is to replace? A walk through guide would be very welcome if you can spare the time.

Thanks

[M100-NC]

Maybe you should VISIT the locksmith and convince him to come and extract the broken key.

Go to http://www.deroure.com/ and search for Part # A082H6038H to get an idea of what the ignition lock looks like.

If you click on the part number that is item #60, it will open up a link to illustration of the steering column and lock.

To remove the steering lock assembly, DISCONNECT THE BATTERY. Remove the covers from the steering column. Locate the ignition switch / steering lock assembly.

The steering lock assembly is held to the steering column with two bolts that no longer have a hex head. They get sheared off when tightened so it is harder to steal the car by unbolting the ignition lock.

Un-plug the ignition switch from the wiring harness.

Either drill the two retaining bolts and use an EZ-Out or, I usually use a dremmel with a small cutter disc to grind a slot in the nubs from the sheared bolts and I use a screw driver to remove the bolts.

Take the ignition lock to your nearest locksmith He should have the broken key portion out in around 2 minutes.

Then, he can make you a new key (or two) using your spare ignition key.

Take the now empty lock assembly back home and screw the ignition lock back in place with the screw driver and put the steering covers back together.

All that because the locksmith wasn't willing to come to you.

[Grogers]

Hi M100-NC

Thanks for taking the time to reply.

In the end, I decided how hard could it be to remove the broken part of the key in the barrel so with only a little time and money to lose I decided to purchase an otoscope (£20) and a broken key removal kit (£4) and give it a try.

It didn’t come out quickly or easily but 25 minutes later it was out and I’m quite pleased that I do not have to go through the ignition barrel removal that you kindly explained in your reply.

[M100-NC]

I am happy that it worked out for you in the end.

[dapinky]

John's explanation is spot-on as to the process - the biggest part of the whole thing is getting access to the 'snapped' bolt heads to cut a groove, but it is actually quite easy to achieve.

When I replaced mine (with a standard Vauxhall Nova/Astra unit) I fitted it with normal headed bolts, not shear bolts, as the chance of theft of vehicle is pretty remote, and the convenience outweighed the originality.