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1996 Toyota Tacoma Ignition Tumbler Replacement

I recently had to fix the ignition switch on my 1996 Toyota Tacoma truck.  The switch suddenly quit working, it would not turn past the "ACC" position.  I took apart the dash to locate the switch assembly and could not identify a way to remove the housing.  So I went to the internet to search for solutions.  Not finding a good description of how to repair, I had to do my own research and trial and error to get it fixed.  To help out others with the same problem, I have documented the solution.

What I did find on the internet is that you need to remove the tumbler assembly to fix the problem.  In order to remove the tumbler assembly, you need to turn the key to the ACC position.  If you cannot do this, you need to drill out the tumbler. This is not a good thing, I think that once you are at this point, you have a lot of work in front of you.  If you do have to drill, hopefully the pictures below will help.

Once the key is in the ACC position, there is a spring loaded pin on the bottom of the assembly that if you push in (upward) and pull on the key, the whole tumbler comes out. There are several holes in the assembly, look at the pictures below to identify the correct hole for the release pin. I used a torx driver to push on the pin.  Initially my key was not turning to the ACC position.    I sprayed in some WD-40 and worked it and and worked it and finally while pushing on the pin, and twisting and pulling on the key, I was able to get it out.  I went to the Toyota dealer and bought a new assembly for $87 and installed the new tumbler.  The switch assembly does have to be in the ACC to reinstall.  Somehow, in my removal and with all the twisting, I was able to remove the tumbler with the switch in the off position.  I used a needle nose to turn the pin to ACC and then the tumbler dropped in nicely.

It appears that the housing for the tumbler is factory installed with bolts that have a head that is broken off after the install.  I checked the parts diagram at the dealer for this part and bolts are shown that validate this approach.  So don't mess up the housing.  Probably designed this way for anti-theft.

Good luck. If I can be of more help, send me an email: mailto:paul@torgerson.com

 

Here are some picture of the assembly:

The housing in the truck, view looking up.  The pin hole for removing the tumbler is at the top of the picture.

 

View across the steering column, from the drivers door.  Tumbler removed.

This shows the pin assembly. This pin is about 1/8 inch and depresses into the housing when the key is in ACC.

Front of the tumbler.

Bottom view of tumbler

Received this from Bruce on 4/23/2007

Thank you greatly for your web post. Yesterday my son's truck had the same problem and we looked at it a long time before giving up and looking on the web. Within 5 minutes after that we had the lock cylinder out.

I rebuilt the lock cylinder by drilling out the pin on the bottom.
Then drilling the two pins on the back side of the front plate just enough so that they would slide out.
Removed the locking washer on the back side.
Slid the cylinder out.
Removed and straightened the bent tumbler.