Steering lock broken, cant get out ignition tumbler

[Techno Duck]

This is on my dads '95 525i. This morning he tried to start the car but couldnt get the key to turn all the way. He said the car was also stuck in park so i initially thought the brake switch was probably bad. I checked the brake lights and they did not turn on, so that is what i figured it was, replaced the switch and no joy.

I should have looked at it a little more as i realized the steering wheel was also stuck locked. What is happening is the key will turn to what i believe is just shy of the #1 accesory position then stop due to the steering wheel lock. I can jiggle the steering wheel all i want while trying to turn the key and it will not release. So i think the common issue of the steering lock assembling breaking happened. I took the console apart so i can atleast put the car in neutral to roll it but with the front wheels locked ill need some dollies to get it out of the driveway and onto a tow truck probably.

Now i tried to pull the ignition tumbler out to see if i can unjam it, but cant get it to budge. I turn the key as far as i can, then stuck a .05 allen wrench (as per previous threads) in about 1". No matter what i tried with pulling on the key i cannot get the tumbler to pull out. So basically i am SOL...ugh.

Any suggestions on getting that lock tumbler out?

To illustrate things, here is the key inserted (not turned)

http://img.photobucket.com/albums/v120/TechnoDuck/lock.jpg

And here is as far as i can turn the key before it stops.. you can see the allen key in the hole.

http://img.photobucket.com/albums/v120/TechnoDuck/lock1.jpg

[alex 1993 525i auto]

I had a similar problem with the barrel jammed in like yours. You have to remove the steering wheel 1st (0 = unplug the battery, caution to the airbag), and the upper and lower covering (better remove the lower trim panel 1st) to uncover the steering lock aluminum device. You need torx bitset to remove the airbag from the steering wheel, the screw are not super accessibles behind the wheel. There are write-ups and photos if you look for it, I used those very well done write-ups:

Steering lock assembly removal and replacement (http://www.bimmerboard.com/forums/posts/566688)
Steering lock replacement (http://www.bimmerboard.com/forums/posts/779065/)

even my story on replacing that;
http://www.bimmernut.com/forum/5-series-bmw/42992-ignition-lock-difficult-turn-doesnt-come-back-position-easily.html
Ignition lock difficult to turn and doesn't come back to ON position easily (http://www.bimmerboard.com/forums/posts/814535)

Not that difficult job, just get the tools (small rotary tool with cutting wheel, a good snap-ring pliers, a T20 torx bit, a clamp or wrench (see bimmerboard post 779065) etc.), its a 2 hours job or so when it's 1st time.

With you steering lock in your hands if you cannot remove the barrel it's because it's retaining little plastic square is stuck even if you insert the small allen key in the hole near the key. Did you try pulling very hard the key in every different position (turn the key 0.5mm or so at the time then pull hard)? If not no choice buy a new ignition tumbler with the steering lock. If you're not in a hurry (and can spend extra $60-$80 extra) better buy the coded key from the dealer or if not you'll have different keys for doors/trunk and ignition.

Best luck,
Alex

[Techno Duck]

Alex, thanks for the write up and the links. I figured removing the wheel and the entire steering lock assembly was the next step. Was too lazy to do it though! I hoped getting the ignition tumbler out would allow me to atleast unlock the wheel so i could move the car.

I spent about 30 minutes messing around with ignition tumbler trying to get it out, but havent had any luck. Tried everything from paper clips, allen keys and even a punch. Also tried tapping with a hammer...etc. And getting pretty forceful with it. I am pretty sure its jammed. I found some videos on YouTube showing how to remove the tumbler, i saw i was actually off in my above pictures, having turned it too far. Even now doing it the 'correct' way and even trying turning the key a little at a time i havent had any luck.

I was hoping to just tow the car to a friends place (mechanic) who said he would work on it, too cold to be outside right now. But looks like i have no choice!

[genphreak]

Its a common issue, search the forum and you will find your answer. You have to extract the barrel with a special procedure, fix ti and re-insert. Need a small allen key, patience and skill- or a special tool to do it.

[Techno Duck]

Just wanted to follow up, the long metal rod that engages the ignition switch inside the steering lock housing broke, so this was not allowing the key to turn all the way. Even after removing the steering lock housing and placing it in a bench vice, i was unable to get the ignition lock tumbler out. I know i was doing it right because i could get the new tumbler i ordered out.. i ended up drilling a tiny hole where the tab sticks out, once i did that and pushed in on the tab i was able to pull it out. Basically the entire thing had been pretty gummed up.

Anyhow i ordered a new steering lock housing and ignition lock tumbler from BMW. Total cost was about $200 through my dealer account. Only issue i had was the steering lock housing was defective out of the box.. the entire metal rod (which broke on the old one) pulled out of the assembly when i was installing the new lock tumbler. There is a metal pin which has the ends peened that holds everything in place.. it was not done correctly and fell out with only minor handling. Should have a new one tomorrow morning.

[Tiger]

Suggest you wiggle the allen key in more... push the key and tumbler in more and then if the allen key go in more then try pulling the tumbler out.

[Techno Duck]

Some pictures to help illustrate things for future readers;

This is the original steering lock housing, you can see the hole i had to drill to get the ignition lock tumbler out.

http://img.photobucket.com/albums/v120/TechnoDuck/IMG_0336.jpg

Broken metal shaft on the inside. The bottom is the broken one (its in 3 pieces). The top one is what the shaft should look like.. though note the shaft should not come out of the lock housing, the housing i got from BMW was defective and this entire piece pulled out of the steering lock housing.

http://img.photobucket.com/albums/v120/TechnoDuck/IMG_0337.jpg

Part cost break down through dealer account.. your cost may be more expensive.

Ignition lock tumbler keyed for my dads car - $86
Steering lock housing - $118.14

The repair isnt too difficult and is covered well here,

Steering lock assembly removal and replacement (http://www.bimmerboard.com/forums/posts/566688)

[genphreak]

if you need a last resort option, find someone with a late model wreck, eg a '95 like yours, and buy the entire steering column. Swap it over- but first, with the old column out on a bench, set about removing the barrel as it is pretty tricky. Try making the proper tool- if you can't a locksmith (and the best instructions you can find on the web) will be able to do it.