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datatrain · Posted: Tue Nov 18, 2008 8:55 am Post subject: Changing ignition switch help

The horn pulled off easily. The wheel came off easily.

Now I look at it and it doesn't look too much like I've seen in other posts on this topic. There are 4 screws, not 3 holding the switch gear in place. No problem so far. BUT, there doesn't seem to be any screws holding the top and bottom plastic covers. I expected to find 2 screws on the underside. There is nothing !
How do I get the covers off ? Does it snap on. I hate snap on's cos they break when they get old. If I remove the stalk switches will it become obvious ? I don't want to charge blindly ahead and break something.

Twenty years ago, I'd have gone at 'er and probably paid the price.

Thoughts pls.

Thnx
_________________
'78 924 NA with Collector plate
33 year old car, with me for 21 yrs
Mint '92 318i BMW
Near mint '98 Buick LeSabre
VE7HFR

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

Keep disassembling. It will make sense once the switches are out of the way.

Also, unplug the electrical connections to the switches BEFORE pulling them. There are two plastic connectors you will see after jamming your body upside down into the footwell.

Have fun!
_________________
Toofah King Bad

WeiBe (1987 924S 2.5t) - 931 S3

datatrain · Posted: Tue Nov 18, 2008 9:45 am Post subject:

So far so good. the connectors came off easily and the switch gear just slid out.

Now I still don't see how to get the cover off so I can remove the spacer.

From behind the dash there is a small tab that appears to latch the plastic cover behind the cast housing. Trouble is the plastic is behind the casting out front so releasing the tab wont work.

The plastic cover appears to be one piece. From what I see it has to come off or I can't remove the spacer which is firmly in place. I think it'll be a box cutter job to remove.

Do I need to remove the spacer with the cover on and once removed will the casting slip off ?

Thnx
_________________
'78 924 NA with Collector plate
33 year old car, with me for 21 yrs
Mint '92 318i BMW
Near mint '98 Buick LeSabre
VE7HFR

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

Hmm, am I remembering two long black phillips screws, one on each side, inserted into the lower half?

I think you still may need to remove that big circlip and pull off the cast assembly before the plastic bits come off.

Sorry I can't remember better. . .I have done two of these in the last year, one of each style. . .the details are blurring a bit.
_________________
Toofah King Bad

WeiBe (1987 924S 2.5t) - 931 S3

datatrain · Posted: Tue Nov 18, 2008 10:07 am Post subject:

No long black screws any where.

If I cut off the spacer and remover the clip from in front of the bearing and I've already removed the allen key in a attempt to get room to pull the plastic to no avail. Will I have access to the switch ? I assume its on the back side of the casting. The more I look at the plastic the more I think it's one piece tapered.

Is the casting usually tight and with the plastic in place how do I grab it to pull hard ?

Getting dark now so not enough ambient light to continue today. Tomorrow will be a day of make 'er or break 'er. Hopefully the former.

Thnx
_________________
'78 924 NA with Collector plate
33 year old car, with me for 21 yrs
Mint '92 318i BMW
Near mint '98 Buick LeSabre
VE7HFR

Smoothie · Posted: Tue Nov 18, 2008 10:11 am Post subject:

Yes, talking the trim "bezels" between steering wheel and dash, right? They should be held together with 2 small-head phillips screws - one at each side and screwed upward from lower to upper half. After unscrewing, the lower half should come off easily, while the upper half will have to be bent a bit while pulling it off. -Or since you're removing the lock holder, you could leave the upper half in place and remove it along with the holder. There should be enough room to remove the black spacer with just the lower half of the bezel removed.

To remove the cast assembly that holds the lock and switch, you'll at least have to remove the black plastic spacer from the shaft, and the hex socket head screw that's accessible through a hole in the bottom of the dash.
The arrow in this pic happens to be pointing at that socket head screw -

_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

The black spacer hoo-hah, I just pulled off with channel locks.
_________________
Toofah King Bad

WeiBe (1987 924S 2.5t) - 931 S3

datatrain · Posted: Tue Nov 18, 2008 10:19 am Post subject:

Sorry, there ain't no shtinkin screws in the bezel. It appears to be one tapered piece. I've climbed under a couple of times to check. It's all as smooth as a baby's bum. No screw holes and no dividing seam.

SO I guess I'll be doing it the hard way.

Thnx
_________________
'78 924 NA with Collector plate
33 year old car, with me for 21 yrs
Mint '92 318i BMW
Near mint '98 Buick LeSabre
VE7HFR

RC · Joined: 25 Mar 2007 Posts: 2637 Location: Australia

datatrain · Posted: Wed Nov 19, 2008 4:46 am Post subject:

Here are some pics.
Any idea how I can grab the casting and pull it out. There is almost no space for a puller and also only 2 grab spots both on the same side.
_________________
'78 924 NA with Collector plate
33 year old car, with me for 21 yrs
Mint '92 318i BMW
Near mint '98 Buick LeSabre
VE7HFR

datatrain · Posted: Wed Nov 19, 2008 4:54 am Post subject:

You can see it's very tight. Ideas would be appreciated.

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_________________
'78 924 NA with Collector plate
33 year old car, with me for 21 yrs
Mint '92 318i BMW
Near mint '98 Buick LeSabre
VE7HFR

Smoothie · Posted: Wed Nov 19, 2008 6:51 am Post subject:

I never had to use anything other than my bare hands to pull the casting out. Have you tried it with the key in and turned to unlock the steering? -Can't actually remember if that's necessary, but give it a try.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

That black plastic collar is keeping the housing from sliding off. Pull it off with channel locks.
_________________
Toofah King Bad

WeiBe (1987 924S 2.5t) - 931 S3

datatrain · Posted: Wed Nov 19, 2008 7:44 am Post subject:

Okay so here's the scoop.
The spacer was removed in the pics.
.
I had to remove the casting by getting behind the dash. A flat punch and some gentle tapping pushed it out. Putting it back required some gentle tapping with a wooden block. And the key was turned on.

The entire assembly and the bezel came out together.

So it's done and it works but the original problem of leaking battery voltage when the ignitions turned off is still there. Now I am truly baffled.

Thanx to all for the suggestions.
_________________
'78 924 NA with Collector plate
33 year old car, with me for 21 yrs
Mint '92 318i BMW
Near mint '98 Buick LeSabre
VE7HFR

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

Okay me freakin bonehead, sorry
_________________
Toofah King Bad

WeiBe (1987 924S 2.5t) - 931 S3