93-95 Ignition Lock

[Robert Bauer]

I  recently replaced my ignition lock.  I thought I'd post this because this
is a common problem.  The dealer wants about $250 for labor and $55 for
parts.  The parts you can't avoid, however a few hours and your back in
business.  The only disclamer is I didn't have the torque specs for the
bolts.  I wrote this down after I did the procedure but I don't think I
forgot anything.  Let me know if I did.

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93-95 Audi 90 quattro Steering Lock Replacement Procedure (may work on other
years and models)

Required Tools:
Dental Pick
Philips Screwdriver
T30 Tamper Resistant Torx
T30 Torx - this isn't truly required because you can use the T30 tamper
resistant.
Ratchet
24mm Socket
13mm Wrench
13mm Socket

Helpful Tools:
Universal 13mm Socket or universal joint
Small flat screwdriver

To begin the wheels should be straight.

Disconnect the airbag
The airbag connection is located under the lower left side of the drivers
dash.  Pop the cover off, remove the connector and disconnect.

Remove the ignition switch rubber boot
Use a dental pick and carefully slide in behind the rubber boot and remove
it.  Be cautious not to tear the boot.

Remove the Steering column trim.
The steering column trim is held in place by two philips screws on the
underside of the column.

Remove the Steering wheel
Be sure you have disconnected the airbag before proceeding.
The airbag is secured by two T30 torx bolts on each side of the back side of
the steering wheel.  The airbag also has a wire connecting it to the wheel.
It is not necessary to remove this from the airbag unit.  Simply flip the
airbag through the steering wheel and rest it on the column and wheel.
Disconnect the wire coming from airbag/wheel located on the right hand side
of the steering column closest to the dash.  Next remove the 24mm nut
holding the steering wheel on the steering column.  Set the airbag back in
place and remove the steering wheel.  Be careful of the plate on the rear of
the steering wehel.  It contains a coiled wire for the airbag.  While it isn
’t a big deal if it separates it will save you time not having to recoil it.

Remove the instrument cluster
The instrument cluster is held in place by two philips screws at the base of
the cluster that were exposed when the column cover was removed.  Remove
these screws.  The instrument cluster can then be lifted out of the dash.
There are five connections attached to the cluster.  Remove the blue and
yellow connection by prying up the purple tabs with a small flat
screwdriver.  The hard wired bulb is usually tight but it just twists to
come out.  The others are just as simple.

Remove the lower dash
The lower dash is secured with four bolts two have covers over the access
holes.  To remove the covers slip a dental pick between the dash and the cap
and the dash and pry them out.  A bit of pressure is needed to remove these
so be careful not to damage your dash.  Remove the four bolts and remove the
lower dash being careful of the airbag connection you disconnected in the
first step.  Follow by removing the connector on the back of the ignition
lock.
Note: I did not try to replace the lock at this point, however it might be
possible if you could get at the setscrew for the lock.  You may want to try
it and skip the next few step of removing the shaft.

Disconnect the shaft
The steering shaft is connected using two 13mm nuts at the floorboard.  This
is a bit tricky but persistence will pay off.  There are two additional
bolts and two nuts securing the column in place that must be removed.  The
two bolts securing the column in place are just below where the instrument
cluster sat.  The two nuts are about mid shaft.

Remove the multi-switches
The multi switches are held in place by a 4mm hex bolt on the underside of
the column.  This bolt does not need to be removed.  It only needs to be
loosened until the multi switches can be removed.

Remove the steering column
With some work you can now remove the entire shaft.  The easiest and maybe
the only way, is with the bottom of the shaft near the gas and the top by
the door.  It’s a pain but it does come out.

Remove the ignition lock
The ignition lock is held in place by a T30 tamper resistant torx bolt.
Back this bolt out enough to remove the lock assembly.

Remove the tumbler
The tumbler is held in place with a retaining spring that is accessed via a
small hole on the bottom side of the lock.  Press the spring with a dental
pick and remove the tumbler.
Install the tumbler
The tumbler is keyed to ensure proper alignment.  Simply align them and push
it in until it clicks.  Test it with a key.  Remove the plastic cap on the
top of the lock housing and snap it on the new lock.

Install the new lock

Install the new lock assembly in the column and secure with the setscrew.

Put it all back together
Reverse the order and put it all back together.


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Let me know if you have any questions.

Thanks,

Robert Bauer