Ignition Switch

This procedure covers the removal and replacement of the ignition switch on a 2007 Ram 3500 with 5.9L Cummins diesel engine, which is located in the steering column.

Warnings

Tools required

Parts

• Ignition switch × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition key to ON position for 10 seconds without starting, then turn to OFF and remove key
3. Disconnect negative battery cable and wait at least 2 minutes for airbag system discharge
4. Adjust steering column to lowest and fully extended position for best access
5. Position driver's seat as far back as possible to create working room

Procedure

1. 1

   Remove lower steering column covers
   Remove the knee blocker panel below the steering column by pulling outward to release clips. Remove the two Phillips screws at the bottom of the lower steering column cover. Separate the lower cover from the upper cover by releasing the side clips and removing downward.
2. 2

   Remove upper steering column cover
   With the lower cover removed, locate and remove the Torx screws securing the upper column cover (verify T15 or T20 size against the actual fasteners). Carefully lift the upper cover away from the column, feeding the PRNDL indicator cable through the opening if equipped with a column shifter. Set covers aside in a safe location.
3. 3

   Disconnect wiring from ignition switch
   Locate the ignition switch electrical connector on the right side of the steering column. Depress the locking tab and disconnect the connector. Note the orientation of the connector for reinstallation. There may be multiple connectors - identify the ignition switch connector by tracing it from the switch body rather than relying on pin count or color.
4. 4

   Release ignition switch locking tab
   Locate the small access hole on the side of the steering column housing near the ignition switch mounting area. Insert a small punch or 1/8 inch drill bit into this hole to depress the internal locking tab. You will feel a slight click when the tab is depressed.
5. 5

   Remove ignition switch from lock cylinder
   While holding the locking tab depressed with the punch, use a flat-blade screwdriver to carefully rotate the ignition switch counterclockwise approximately 1/8 turn. The switch should release from the lock cylinder housing. Pull the switch straight out from the column.
6. 6

   Inspect lock cylinder actuator
   With the switch removed, inspect the lock cylinder actuator rod for damage or excessive wear. The rod should move freely when the lock cylinder is rotated (if key is available). Clean any debris from the mounting area with compressed air or a clean cloth.
7. 7

   Install new ignition switch
   Align the new ignition switch with the lock cylinder actuator rod. The switch should have a slot that engages with the flat on the actuator rod. Push the switch into the housing while rotating slightly clockwise until you hear/feel the locking tab engage with a distinct click.
8. 8

   Reconnect electrical connector
   Connect the electrical connector to the new ignition switch, ensuring the locking tab clicks into place. Gently tug on the connector to verify it is fully seated and locked.
9. 9

   Reinstall steering column covers
   Position the upper steering column cover over the column, routing the PRNDL cable through the opening if equipped. Secure with the two Torx screws. Install the lower cover by aligning the clips and snapping into place, then install the two Phillips screws. Reinstall the knee blocker panel by aligning and pressing until clips engage.
10. 10

    Reconnect battery and test
    Reconnect the negative battery cable. Turn the ignition key through the LOCK, ACC, and ON positions and verify smooth operation and proper electrical function. Briefly cycle to START only to confirm the starter engages, being prepared for the engine to crank/start. Check that all accessories operate correctly in the ACC and ON positions.

Reassembly

1. Ensure all steering column covers are properly secured with no loose clips or screws
2. Verify knee blocker panel is fully seated and does not rattle
3. Check that PRNDL indicator cable is properly positioned and visible through column cover opening if equipped

Verification

• Turn ignition key to ACC position - radio and accessories should power on
• Turn ignition key to ON position - instrument cluster should illuminate, check engine light and wait-to-start light should function normally
• Turn ignition key to START position - starter should engage (engine will crank)
• Verify key returns to ON position after releasing from START position
• Confirm all dashboard warning lights function properly with ignition in ON position
• Test that key can be removed only in LOCK position
• Verify steering wheel locks when key is removed and column is turned slightly

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