[img]smileys/smiley19.gif[/img] What a PITA to take apart! [img]smileys/smiley7.gif[/img]
Edited by: tsmith1947

Really? I've done a couple. It wasnt that bad.

I got as far as splitting the cowling. Can't get the bottom piece off the key/switch. The screws kind of threw me since they were larger than a 5mm and smaller than a 6mm. Then the access to the two recessed ones was smaller than the 7/32 socket. Been quite a battle and the Saturn has won I'm afraid. I cannot remove the key from the ignition switch. But at least the start and drive function works so I can get it to a shop on Monday.
Edited by: sw2cam

For future reference, when removing the steering column shroud, its a 5.5mm socket. Get a deep 5.5mm socket and a drill bit slightly larger in diameter than the socket then drill out the recess. It'll only remove a small shaving of plastic. Just enough for the deep 5.5mm socket to reach the screw and no bind up.

To remove the ignition lock cylinder, keep the key in the ignition, and depress the locking pin at the rear of the lock cylinder. Rotate the cylinder and remove the locking pin. Then remove the cylinder from the case.

Then go to your friendly neighborhood Saturn parts department and get a new cylinder. They can code the cylinder to match your existing keys. Might also want to pick up a new key as well.

Thanks Mike. My frustration was showing a bit. :-)

My socket-size and recess tunnel clearance issue was solved in my typical "why do it the easy way" manner. I took an old cheap 7/32 and liberally applied grind stone until it fit the tunnel.

Since there was a big cloud of smoke released from somewhere in the area of the switch, I'll probably have to replace the plastic relay/contact (?) housing on the bottom part of the switch also. Never a dull moment.

Thanks for your help and advise.
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I realized something last night after I turned my computer off. I had this same exact problem in my 1993 SW2. The problem want with the ignition cylinder, but the housing it goes into. Your cylinder may be fine. what it slides into and what the electrical connector plugs into most likely needs replacement. I grabbed one from the junkyard.