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xcbxer

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  • From
    Toronto
  • Porsche Club
    No
  • Present cars
    1997 boxster
  • Future cars
    more boxsters
  • Former cars
    jaguar E type
    Bug Eye Sprite
    1600 MGA

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  1. My recently acquired 97 boxster (40K miles) came with an ignition switch which was consistently notchy going from 0 to 1. A few times it would not budge. Jiggling the steering wheel and key became tiresome. Never saw any electronic misbehaviour. First, I went under the dash and pulled the electric switch. Part number was 4A0 905 849 B and obviously had been replaced in the past. With the electric switch disconnected the key still resisted going from 0 to 1, but only after the key was pulled out. If the key stayed in the tumbler there was no notchiness. I concluded that the steering lock disengagement was the culprit. Next day I pulled the left side vent and instrument cluster to remove the steering lock. The instrument cluster took 10 minutes and fully exposed the work area - (hats off to those who succeeded thru the vent hole alone). Once the lock assembly was on the bench, why not take it apart before ordering a new one. There is a square plate crimped in by the aluminum casting. It can be carefully pryed out to expose the steering lock disengagement cam. With the tumbler and electric switch off, using a screw driver to simulate the key and with one thumb standing in for the spring, I easily duplicated the original notchiness. Maybe it's no surprise with this mechanism's many rotational and longtudinal friction points, endless mechanical gyrations and tight tolerances. I intended to remove the circlip from the tumbler end and strip out the locking plunger, thus leaving the car without steering lock. With encoded keys who needs the steering lock function? However, laying down some molybdenum EP grease on the cam totally eliminated the notchiness. I then sprayed in some McLube (or use Jigaloo) and closed up the gizmo. For now problem solved - cost zero. If it acts up again somewhere down the road, I'll pull the plunger.
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