Carina E Cdx ('96) - Key Broken In Iginition Lock

[Milo]

Wife broke key off in ignition lock - key is chipped so Toyota wanted £164 plus for lock barrel plus key chipping so little change expected from £225. So hope this helps anyone else with same predicament....

The key barrel is easy to remove:

Remove lower facia panel under the steering column - 2 screws then pull away.

The broken key stub should still operate the lock, so switch it so key is at 12 o'clock - under the barrel there is a small brass pin which with the key in the 12 o'clock position will push up with a small screwdriver. At same time using the key pull the barrel assembly free.

1. Remove black plastic ring from front.

2. Drill off two rivet heads holding barrel facia plate - drill just enough to knock the plate off with a small drift pin in the back of the rivet - remove the facia plate.

3. remove the C clip from the rear of the barrel - the barrel should now come out from the housing.

4. tap out the lock entry key piece or tape over it so it does not drop out and get lost.

5. from the rear of the barrel drill down through the slot (which engages on the operating shaft), the drill will come out and be visible again in a square opening in the casting, carefully drill on down into the rear section of the barrel. The drill should break through just behind the end of the key.

6. put clingfilm round the brass key tumblers then using a fine stiff wire down the drilled hole push the broken section of key out.

7. Fit bit from step 4 if removed, insert a spare key, remove clingfilm and reassemble barrel into housing. Fit C clip and remove key.

8. lightly countersink the housing to allow remainder of rivet to be peened back to hold facia on (use a centre punch to peen rivet over). (An alternative would be araldite.)

9. Finish reassembling.

Sounds like a lot but the whole job took me about 20 minutes. :D