91 Explorer ignition cylinder removal.

mdsch061 · 07-06-2010, 09:49 PM

I have followed all the threads and there is no pin to release the cylinder on a 91. My other issue is the key only goes in 90% and it will not turn. Anybody have any suggestions how to remove the cylinder ??

**BrooklynBay** · 07-09-2010, 09:18 AM

Welcome to this forum! I've moved your thread into the stock 91-94 section.

*92exp4x4* · 07-09-2010, 06:29 PM

Not fun. If you cannot get the key all the way in you are in for some work.

Try, try, try again to get the key into the cylinder. You will need the remove the steering wheel and the column plastics. I remove the dash panel first, it makes it easier to get the other stuff off.

If you can get the key in, turn the ignition to on position and you will need to stick a piece of coat hanger into a bore only accesible from the bottom side of the column casting. There is a small lock pin that pushes in and then the cylinder will slide out. I will try to get you a pic.

If you can't get the key in the lock, you will need to drill out the cylinder with a 1/4 inch bit. I spent a little over three hours doing this one day. Its hard to get it to go down the center. Be careful not to damage the casting, its only aluminum. There is also a gear and slide mechanism behind the lock cylinder to move the actual ignition switch. You don't want to damage these either.

*92exp4x4* · 07-09-2010, 07:13 PM

The first pic is the column as you see it sitting in the seat. My finger is where the key cylinder goes. There is a smooth round part of the casting just to the left of my finger under the lock cylinder case, going perpendicular to it. That is what is bored out, its circled with red.

The second pic shows the bore, again at the tip of my finger. Its about 3/4 of an inch deep. I used a piece of coat hanger. You do not have to remove the steering wheel mount. I have it removed for clarity.

Hope this helps, let us know how it works out.

mdsch061 · 07-09-2010, 11:20 PM

Quote:

Originally Posted by 92exp4x4

The first pic is the column as you see it sitting in the seat. My finger is where the key cylinder goes. There is a smooth round part of the casting just to the left of my finger under the lock cylinder case, going perpendicular to it. That is what is bored out, its circled with red.

The second pic shows the bore, again at the tip of my finger. Its about 3/4 of an inch deep. I used a piece of coat hanger. You do not have to remove the steering wheel mount. I have it removed for clarity.

Hope this helps, let us know how it works out.

Thank you so much for the advice and the pics. I was able to get the slid gear to move back and forth, but no luck with the key turning. I think the last cylinder key wafer colapsed in the keyway or the entire cylinder cratered inside. I will work on it tomorrow and get back to you if successful with the drill.

Exploderman09 · 07-21-2010, 11:29 PM

I have a 93 explorer...didnt have to bore the hole, it was already there. But extremely helpful on getting it out. Thanks!

*92exp4x4* · 07-23-2010, 05:12 PM

No problem, that is what this forum is for.

07-06-2010, 09:49 PM	#1
mdsch061 Wannabe Elite Explorer Texas 91 xlt Join Date: Jul 2010 Posts: 2 Vehicle Specs (Original Poster)	91 Explorer ignition cylinder removal. I have followed all the threads and there is no pin to release the cylinder on a 91. My other issue is the key only goes in 90% and it will not turn. Anybody have any suggestions how to remove the cylinder ??

07-09-2010, 09:18 AM	#2
BrooklynBay Aerostar Forum Moderator Brooklyn, NY 88 89 93 95 96 Aerostars Join Date: Nov 2005 Posts: 45,680 Vehicle Specs	Welcome to this forum! I've moved your thread into the stock 91-94 section. __________________ My list of useful threads. My photo gallery. My product reviews. My list of items for sale. Aerostar owners thread. Aerostar parts work in Explorers, Rangers, and Bronco II thread. History of the Aerostar thread. Aerostar Forum. New Members Forum. Ford/Lincoln/Mercury Forum.

07-09-2010, 06:29 PM	#3
92exp4x4 Elite Explorer Covington, Kentucky 92 XL 2-door and others Join Date: Feb 2003 Posts: 901 Vehicle Specs	Not fun. If you cannot get the key all the way in you are in for some work. Try, try, try again to get the key into the cylinder. You will need the remove the steering wheel and the column plastics. I remove the dash panel first, it makes it easier to get the other stuff off. If you can get the key in, turn the ignition to on position and you will need to stick a piece of coat hanger into a bore only accesible from the bottom side of the column casting. There is a small lock pin that pushes in and then the cylinder will slide out. I will try to get you a pic. If you can't get the key in the lock, you will need to drill out the cylinder with a 1/4 inch bit. I spent a little over three hours doing this one day. Its hard to get it to go down the center. Be careful not to damage the casting, its only aluminum. There is also a gear and slide mechanism behind the lock cylinder to move the actual ignition switch. You don't want to damage these either. __________________ My stable: 2 doors - '91 Eddie Bauer; '92 XL 5 speed; '92 Sport 2WD 5 speed 4 doors - '91 XLT; '93 XLT; '94 XLT, 6" lift, 33's; '94 Eddie Bauer 5 speed; '94 Limited Others - '22 Model T, '48 8N tractor, '62 Fairlane 500, '93 F-Superduty 460, '97 F250 Powerstroke, '04 F550 service truck (company owned)

07-09-2010, 07:13 PM	#4
92exp4x4 Elite Explorer Covington, Kentucky 92 XL 2-door and others Join Date: Feb 2003 Posts: 901 Vehicle Specs	The first pic is the column as you see it sitting in the seat. My finger is where the key cylinder goes. There is a smooth round part of the casting just to the left of my finger under the lock cylinder case, going perpendicular to it. That is what is bored out, its circled with red. The second pic shows the bore, again at the tip of my finger. Its about 3/4 of an inch deep. I used a piece of coat hanger. You do not have to remove the steering wheel mount. I have it removed for clarity. Hope this helps, let us know how it works out. Attached Images __________________ My stable: 2 doors - '91 Eddie Bauer; '92 XL 5 speed; '92 Sport 2WD 5 speed 4 doors - '91 XLT; '93 XLT; '94 XLT, 6" lift, 33's; '94 Eddie Bauer 5 speed; '94 Limited Others - '22 Model T, '48 8N tractor, '62 Fairlane 500, '93 F-Superduty 460, '97 F250 Powerstroke, '04 F550 service truck (company owned)

07-23-2010, 05:12 PM	#7
92exp4x4 Elite Explorer Covington, Kentucky 92 XL 2-door and others Join Date: Feb 2003 Posts: 901 Vehicle Specs	No problem, that is what this forum is for. __________________ My stable: 2 doors - '91 Eddie Bauer; '92 XL 5 speed; '92 Sport 2WD 5 speed 4 doors - '91 XLT; '93 XLT; '94 XLT, 6" lift, 33's; '94 Eddie Bauer 5 speed; '94 Limited Others - '22 Model T, '48 8N tractor, '62 Fairlane 500, '93 F-Superduty 460, '97 F250 Powerstroke, '04 F550 service truck (company owned)

07-21-2010, 11:29 PM	#6
Exploderman09 Wannabe Elite Explorer Fridley, MN '93 XLT--MAN Tranny Join Date: Aug 2008 Posts: 9 Vehicle Specs	I have a 93 explorer...didnt have to bore the hole, it was already there. But extremely helpful on getting it out. Thanks!