Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD1994F 150 2WD PICKUP L6-300 4.9LREPAIR AND DIAGNOSISSTARTING AND CHARGINGSTARTING SYSTEMIGNITION LOCKSERVICE AND REPAIRLOCK CYLINDER NON-FUNCTIONAL
1994 Ford F 150 2WD Pickup L6-300 4.9L
Lock Cylinder Non-Functional
1994 Ford F 150 2WD Pickup L6-300 4.9LSECTION Lock Cylinder Non-Functional
NOTE: The following procedure applies to vehicles in which the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken lock cylinder key, unknown key number, or a lock cylinder cap that has been damaged and I or broken to the extent that the lock cylinder cannot be rotated.
Removal
1. Disconnect battery ground cable.
2. Remove steering wheel. Refer to Steering Wheel: Service and Repair.
3. Using channel lock pliers or vise grip pliers, twist lock cylinder cap until it separates from the lock cylinder.
4. Using a 3/8-inch diameter drill, drill down middle of ignition lock key slot approximately 44 mm (1-3/4 inch) until lock cylinder breaks loose from breakaway base of lock cylinder. Remove lock cylinder and drill shavings from lock cylinder housing.
5. Remove retainer, washer, ignition switch and actuator. Thoroughly clean all drill shavings and other foreign materials from casting.
6. Carefully inspect lock cylinder housing for damage from the above operation. If damage is apparent, housing must be replaced.
Installation
1. Replace lock cylinder housing, if damaged.
2. Install actuator and ignition switch.
3. Install trim and electrical parts.
4. Install new ignition lock cylinder by turning it to RUN position and depressing retaining pin. Insert lock cylinder into lock cylinder housing. Make sure cylinder is fully seated and aligned in interlocking washer before turning key to OFF position. This will permit cylinder retaining pin to extend into cylinder housing hole.
5. ROTATE lock cylinder. using lock cylinder key, to ensure correct mechanical operation in all positions.
6. Install steering wheel. Refer to Steering Wheel: Service and Repair.
7. Connect battery ground cable.
NOTE: On vehicles equipped with Powertrain Control Module (PCM), when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the PCM processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.
8. Check lock cylinder operation.
Removal
1. Disconnect battery ground cable.
2. Remove steering wheel. Refer to Steering Wheel: Service and Repair.
3. Using channel lock pliers or vise grip pliers, twist lock cylinder cap until it separates from the lock cylinder.
4. Using a 3/8-inch diameter drill, drill down middle of ignition lock key slot approximately 44 mm (1-3/4 inch) until lock cylinder breaks loose from breakaway base of lock cylinder. Remove lock cylinder and drill shavings from lock cylinder housing.
5. Remove retainer, washer, ignition switch and actuator. Thoroughly clean all drill shavings and other foreign materials from casting.
6. Carefully inspect lock cylinder housing for damage from the above operation. If damage is apparent, housing must be replaced.
Installation
1. Replace lock cylinder housing, if damaged.
2. Install actuator and ignition switch.
3. Install trim and electrical parts.
4. Install new ignition lock cylinder by turning it to RUN position and depressing retaining pin. Insert lock cylinder into lock cylinder housing. Make sure cylinder is fully seated and aligned in interlocking washer before turning key to OFF position. This will permit cylinder retaining pin to extend into cylinder housing hole.
5. ROTATE lock cylinder. using lock cylinder key, to ensure correct mechanical operation in all positions.
6. Install steering wheel. Refer to Steering Wheel: Service and Repair.
7. Connect battery ground cable.
NOTE: On vehicles equipped with Powertrain Control Module (PCM), when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the PCM processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.
8. Check lock cylinder operation.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.