Ignition Lock Cylinder

This procedure covers removal and replacement of the ignition lock cylinder on a 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine, including steering column disassembly and lock cylinder release.

Warnings

Tools required

Parts

• Ignition lock cylinder assembly × 1 — Use OEM specification
• Steering column cover clips (if damaged) × 1 — Dorman 76608 or equivalent

Preparation

1. Park vehicle on level surface and set parking brake
2. Turn ignition to OFF position and remove key
3. Disconnect negative battery cable and wait minimum 2 minutes for airbag system discharge
4. Adjust steering column to lowest position and fully extended out toward driver
5. Ensure transmission is in Park (automatic) or gear (manual)

Procedure

1. 1

   Remove lower steering column cover
   Remove the two Phillips head screws from the bottom of the lower steering column cover. Carefully pull the lower cover away from the column, releasing the retaining clips on the sides. Set cover aside with screws. Cover Screws (snug hand-tight, no critical torque spec)
2. 2

   Remove upper steering column cover
   Locate and remove the two screws securing the upper steering column cover. Screw type varies on this generation; verify the correct driver (commonly Torx or Phillips) before removal. Lift the upper cover straight up and off the column, being careful not to damage the key-in-ignition switch wiring if equipped.
3. 3

   Disconnect ignition switch connector
   Locate the electrical connector on the back of the ignition switch assembly (mounted to the lock cylinder housing). Press the release tab and pull the connector straight back to disconnect. Note the connector orientation for reinstallation.
4. 4

   Remove ignition switch mounting bracket
   Using the appropriate Torx driver, remove the bolts securing the ignition switch and bracket to the lock cylinder housing (verify count and driver size for your specific model). Carefully pull the ignition switch assembly away from the lock cylinder. The switch actuator rod will disengage from the lock cylinder.
5. 5

   Insert key and position to RUN
   Insert the ignition key into the lock cylinder. Turn the key to the RUN position (second position, not START). The key MUST be in this position to release the lock cylinder from the housing. If key will not turn, verify steering wheel is not locked.
6. 6

   Locate and depress cylinder release pin
   With the key in RUN position, locate the small release hole on the lock cylinder housing (typically on the lower left side near the key). Insert a small punch, straightened paper clip, or appropriate release tool into the hole and depress the internal release pin approximately 1/8 inch. You should feel a slight click or resistance release.
   ⚠Do not force release pin excessively as internal spring can be damaged. Gentle pressure with key in correct position is sufficient.
7. 7

   Remove lock cylinder from housing
   While maintaining pressure on the release pin, gently pull the lock cylinder straight out of the housing using the key as a handle. The cylinder should slide out smoothly. If resistance is felt, verify key is in RUN position and release pin is fully depressed. Remove key from old cylinder and set aside.
8. 8

   Install new lock cylinder
   Insert the new key into the new lock cylinder and turn to RUN position. Align the lock cylinder with the housing opening, ensuring the actuator tab on the back of the cylinder aligns with the slot in the housing. Push the cylinder firmly into the housing until it clicks into place. The release pin should automatically engage.
9. 9

   Verify lock cylinder operation
   Turn the new key through all positions: OFF, RUN, and START (do not hold in START without battery connected). Verify the key returns to RUN position when released from START. Turn key to OFF and verify key can be removed. Reinsert key and verify smooth operation through all positions.
10. 10

    Reinstall ignition switch assembly
    Position the ignition switch assembly to the lock cylinder housing with the key in OFF position. Align the actuator rod with the slot in the back of the lock cylinder. Push the switch assembly onto the housing and install the two mounting bolts hand-tight, then torque to specification. Reconnect the electrical connector until it clicks.
11. 11

    Reinstall steering column covers
    Position the upper steering column cover over the column and seat it properly. Install the two upper cover screws and torque to specification. Position the lower cover ensuring all clips align properly, then install the two lower screws and torque to specification.
12. 12

    Reconnect battery and test operation
    Reconnect the negative battery cable. Insert the key and verify ignition operates correctly in all positions. Test that the engine cranks (should crank but may not start without further procedures). Verify key removal works properly only in OFF position. Check that all dash warning lights function normally.

Reassembly

1. Ensure all steering column covers are properly seated and all clips engaged before driving
2. Verify no wiring is pinched between column covers that could cause electrical issues
3. Test all steering column functions including turn signals, wipers, and cruise control switches

Verification

• Key turns smoothly through all ignition positions without binding
• Key can only be removed in OFF position
• Engine cranks normally when key turned to START position
• All dashboard warning lights illuminate with key in RUN position
• Steering wheel lock engages when key is removed and disengages when key is inserted
• No abnormal noises from steering column during operation

Related trouble codes on this vehicle

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