Ignition Switch

This procedure covers removal and replacement of the ignition switch assembly on the steering column of a 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Ignition switch assembly × 1 — Use OEM specification
• Steering column cover clips (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Turn ignition key to LOCK position and remove key
3. Disconnect negative battery cable and wait minimum 2 minutes for airbag system capacitor discharge
4. Position front wheels in straight-ahead position
5. Tilt steering wheel to lowest position for access
6. Gather all tools and replacement parts before beginning

Procedure

1. 1

   Remove lower steering column covers
   Remove the two lower steering column cover screws using appropriate Torx driver. Carefully separate the lower cover from the upper cover by releasing the retaining clips on each side. Pull the lower cover away from the column and set aside. Note the location of any wiring harness clips attached to the cover for reinstallation.
2. 2

   Remove upper steering column cover
   Remove the upper steering column cover screws using appropriate Torx driver. Lift the upper cover up and over the steering wheel hub, being careful not to damage the turn signal stalk or wiper stalk. If equipped with tilt steering, you may need to adjust the tilt position for clearance. Set the upper cover aside in a clean location.
3. 3

   Disconnect ignition switch electrical connectors
   Locate the ignition switch electrical connector(s) on the right side of the steering column below the lock cylinder. Press the locking tab on the main ignition switch connector and pull straight out to disconnect. On models with Park lock-out, disconnect the secondary connector as well. Mark or photograph connector positions if multiple connectors are present.
   ℹ️Some model years have a single connector while others have two connectors - verify which configuration your vehicle has before proceeding.
4. 4

   Remove ignition switch mounting screws
   Locate the ignition switch mounting screws on the steering column (typically Torx head). Screw count and exact position vary by column type — consult the FSM for your specific model year to confirm location and quantity. Remove both screws using the appropriate Torx driver and retain for reinstallation. Support the switch assembly with your hand to prevent it from falling once screws are removed.
   Torque spec

   Switch Mounting Screws5 Nm (4 lb-ft)
5. 5

   Remove ignition switch assembly
   With mounting screws removed, carefully disengage the ignition switch actuator pin from the lock cylinder rack. This may require gently rocking the switch while pulling it away from the column. The actuator pin on the switch engages a slot in the lock cylinder mechanism - take care not to bend or damage this pin. Remove the switch assembly from the steering column.
   ⚠Do not force the switch off the column. If it does not release easily, verify both mounting screws are fully removed and the actuator pin is properly disengaged.
6. 6

   Inspect lock cylinder and column components
   With the switch removed, inspect the lock cylinder actuator rack for wear, damage, or binding. Verify the rack moves freely through its full range of motion when the key is rotated. Check the mounting surface on the steering column for any cracks or damage. Clean any dirt or debris from the mounting area and actuator mechanism using a clean cloth.
   ℹ️If the lock cylinder rack is worn, damaged, or binds during operation, the entire lock cylinder assembly should be replaced to prevent premature failure of the new switch.
7. 7

   Prepare new ignition switch
   Remove the new ignition switch from its packaging and verify it matches the original switch configuration. Check that the actuator pin moves freely and is not bent or damaged. Position the switch in the OFF or LOCK detent position by moving the actuator slider to match the lock cylinder position. Verify all electrical terminals are clean and free of corrosion.
   ⚠The new switch must be in the correct detent position (LOCK) before installation or it will not engage properly with the lock cylinder rack.
8. 8

   Install new ignition switch
   With the ignition key removed and lock cylinder in LOCK position, align the new switch actuator pin with the lock cylinder rack slot. Carefully push the switch into position on the steering column, ensuring the actuator pin fully engages the rack and the switch mounting holes align with the column threads. The switch should seat flush against the column mounting surface.
   ⚠Ensure the actuator pin is fully engaged in the lock cylinder rack slot before tightening mounting screws. Improper engagement will cause binding and switch failure.
9. 9

   Install and torque switch mounting screws
   Install both ignition switch mounting screws finger-tight, ensuring they thread smoothly without cross-threading. Once both screws are started, use a torque wrench to tighten them to the specified torque in a criss-cross pattern. Verify the switch remains properly seated and aligned during tightening.
   Torque spec

   Switch Mounting Screws5 Nm (4 lb-ft)
10. 10

    Reconnect electrical connectors
    Reconnect the ignition switch electrical connector(s) by aligning the connector body and pushing firmly until the locking tab clicks into place. On models with Park lock-out, ensure both connectors are properly seated. Verify each connector is fully locked by gently tugging on the wire harness - the connector should not pull free.
    ℹ️Ensure connectors are fully seated and locked. Partial connection will cause intermittent electrical problems and may result in no-start conditions.
11. 11

    Reinstall upper steering column cover
    Position the upper steering column cover over the steering wheel hub and lower it into place, ensuring the turn signal and wiper stalks pass through their respective openings. Align the cover mounting holes with the column mounting points and install the retaining screws. Torque the screws to specification, being careful not to overtighten and crack the plastic cover.
12. 12

    Reinstall lower steering column cover
    Position the lower steering column cover beneath the upper cover, aligning the retaining clips on each side. Press firmly to engage all clips until they snap into place. Install the lower cover retaining screws and torque to specification. Reattach any wiring harness clips that were removed from the cover. Verify both covers are securely fastened and properly aligned.
13. 13

    Reconnect battery and perform initial test
    Reconnect the negative battery cable and tighten securely. Without starting the engine, insert the key and verify smooth operation through all ignition positions: LOCK, ACC, ON/RUN, and START. The key should move smoothly between positions with appropriate detent feel. Check that the key can only be removed in the LOCK position. Verify applicable instrument cluster warning lights illuminate in the ON position (cluster indicators vary by model year).

Reassembly

1. Verify all steering column covers are properly installed with all retaining clips engaged
2. Ensure no wiring is pinched between covers or column components
3. Confirm all electrical connectors are fully seated and locked
4. Check that steering wheel tilt and telescope functions operate normally after reassembly

Verification

• Start the engine to verify proper ignition switch operation - engine should crank and start normally
• Test all ignition switch positions: LOCK, ACC, ON/RUN, and START - all electrical systems should function appropriately in each position
• Verify the key cannot be removed except in the LOCK position
• On automatic transmission models, verify the shifter cannot be moved out of Park unless the ignition is in the ON position (Park lock-out function)
• Check that the PRNDL indicator in the instrument cluster accurately reflects gear selector position
• Test all accessories (radio, power windows, wipers) in ACC and ON positions to confirm proper switch operation
• Verify no warning lights remain illuminated on the instrument cluster after starting the engine
• Perform a test drive to confirm all systems operate normally with no electrical issues

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