Ignition Switch Tumbler Removal
I'm doing this particular demonstration on a factory ignition switch for a Datsun 521 pickup. There are others out there that are similar and even more that are completely different. One thing that I've found common to all of them is that you need to be able to rotate the tumblers(lock part) to the "ON" position in order to remove the tumblers. The lock in this switch is a simple, one sided key. Double sided key locks should work on similar principle, but you'd have to deal with two sets of tumblers. I've used this lock pick technique on display cases at work and even a cash register my first day on the job down in Florida. The manager was thrilled to have his cash drawer open, but wasn't sure how to feel about me being able to pick the lock in under a minute with a pair of paper clips. :)
****You can do this in the vehicle if you don't have a key, but you will not be able to remove the tumbler. If you've lost your key or you've bought a rig with no key, this will be a temporary help. I certainly do not condone using it for any sort of illegal activity!****
I think the videos will show things well enough. Basically, you want to hold some rotational force on the lock barrel so that when the tumbler is moved with the screwdriver, it will move slightly clockwise and get caught in the bore of the body and stay there. When each tumbler is out of the channel and in the bore, the lock barrel will rotate. Do not rotate it counter clockwise or you will have to pick the tumblers again.
****You can do this in the vehicle if you don't have a key, but you will not be able to remove the tumbler. If you've lost your key or you've bought a rig with no key, this will be a temporary help. I certainly do not condone using it for any sort of illegal activity!****
I think the videos will show things well enough. Basically, you want to hold some rotational force on the lock barrel so that when the tumbler is moved with the screwdriver, it will move slightly clockwise and get caught in the bore of the body and stay there. When each tumbler is out of the channel and in the bore, the lock barrel will rotate. Do not rotate it counter clockwise or you will have to pick the tumblers again.
I cut the crimped edge off the back of the switch so that I could show you the guts. I had metered the switch already and the only position any of the contacts worked in was START. Not hard to understand why when you see what the inside looks like. If you were really desperate for a working switch, you could do this to yours to clean the contacts. Just be very careful when pulling it apart. When I did it, the pieces went flying, otherwise I'd show you how they go together. Oops. :) Putting it back together is another issue. You might be able to epoxy the black plastic piece to the pot metal housing and get it to stay. Maybe "stake" the housing. I'm not sure what would work to hold it together, so you'll have to figure that out on your own.
If you need an ignition switch and can't wait or even find a factory switch, you can use a universal switch that nearly any parts store will stock. The univ switch will have studs or bolts on the backside for the wiring to mount to instead of spade terminals. Rather than cutting your factory harness, you can make some adapters to jumper between the spade terminals in the harness to the studs on the new switch. This way, if you so find a factory replacement, you can simply pull the adapters and plug the correct switch back in. The vid is mainly about crimping, but you'll see the adapter laying on the bench just as it starts. At this time, I'm not going to go into how to wire in a univ switch, I just wanted to bring this up so you don't cut your harness.