Ignition Switch Replacement (LONG REPLY)

Peter Schulz pcschulz at comcast.net
Tue Mar 22 11:36:29 EST 2005


See below....and please feel free to ask additional questions.


At 11:27 AM 3/22/2005, Abe Berman wrote:
>Does anyone have a decent write-up on this or some BTDT's?  Mine is
>failing to return to the "run" position after cranking, which is not
>too healthy for the starter!
>I searched the archives to no avail.  I know that I've read that
>others have done it on the qlist and s-car list, but I can't find the
>Burlington, VT

I do have an update to the procedure - the steering wheel shaft is held to
the dash assembly by a tapered slide joint - I belive that the concept is
that it will allow shaft compression during a front end accident.  when
re-installing the shaft, ensure that it is securely fastened back into
position, by either tapping on the rear of the housing (from the kick panel
area) with a hammer and wood block, or try using a large clamp to pull it
back into place - remember is is a press-friction fit only.  Otherwise you
will find some play in the steering wheel/shaft after putting it all back
together and about 5 000 miles later.

Don't ask me how I know that now  ;^)

This problem is coming up reasonably often now - I need to scan in some of
the pix that I took and set up a web page.....


To: 200q20v <200q20v at audifans.com>
Cc: Dan Simoes <dans at audifans.com>, maximum at weetamoo.com, C1J1Miller at aol.com,
         copley one <copley at snet.net>
Subject: [200q20v] The Audi (Gods) are watching over Alex? (broken ignition

Picked up a second 200q20v Avant about a week ago...Titanium Grey/Platinum
with about 168Kmiles...

The previous owner gave me two different keys - "I had to replace the
ignition (key) switch"...

I thought Hmm, our Indigo Wagon has 162K miles on it...

Picked my wife and newborn son Alex up from the hospital in the Indigo
wagon, and stopped for a sandwich on the way home.

Go to start the wagon - I turn the key to the right, feel and hear a
"pop"  lights come on, but no start.
Take the key out and the lights are still on.


My wife doesn't know whether to cry or rip my head off (Ain't postpartem
depression great ;^)

I'm able to get in touch with her parents to pick her and Alex up, and I
call AAA for a flat bed.

Miracle of miracles, I get home with the car on the flat bed 5 minutes
after she does...and the driver helps me push the car into my garage.
I tip him accordingly.

I then call Mssrs  Paul Royal and Chris Miller to appraise them of the
situation.  Chris orders a new ignition switch for me from Mac at  Clair
Parts Connection.

I spend the rest of the day getting intimate with the interior of the
indigo wagon-with Mr Bentley close at hand.  Steering wheel removal went
easier than I thought.  Pulled out instrument cluster thinking that I could
get to the switch from the top.  No go.

Pull out the knee pad, and proceed to remove the column and support, only
to realize that the support doesn't need to be removed - I then retighten
it.  Removed the multifunction switch cluster. Removed the two 13mm nuts
hold the crushable column section.  Put a block of wood on the column front
and gently tapped it with a hammer - the column slid backwards towards the
firewall. I rotate the column and try to remove the switch assy.  Discover
that it's held in place with a security torx bolt.  I have hex wrenches. I
have torx wrenches and sockets.  But not security torx.


Off to Sears hardware where I luckily find the right bits.

Back to the car - removed the security bolt and pull the switch assembly-
and take it apart.  Find that not only the switch, but the end of the lock
cylinder is broken.  Back on the phone to Mac - luckily they had one lock
cylinder remaining in stock.

Next day, drive to Clair, pick up parts - and decide that I don't want to
deal with having two different keys for the car - SO I have to go to a
locksmith. $40 later it's rekeyed to match the rest of the car.

Stopped to touch up the solder joints on the instrument cluster, and dabbed
Stabilant 22 on the connectors.

1991 200 20v Q Avant Titan Grey
1991 200 20v Q Avant Indigo Mica
1991 90 20v Q Red
1990 CQ silver (awaiting S2 engine transplant)

Chelmsford Ma, USA 

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