how to replace ignition barrel?

Remove the lower cowling "plastic cover" and about 1 - 2 cm from the key lock there is a small round hole, put key in and turn to position 2 whilst pushing in the hole a piece of hard wire, it should depress and pop the lock out, be aware that you may have switched your ignition to the on position, inserting a small blade screwdriver you can switch the ignition off afterwards.
If you have lost the key or the barrel has seized, carefully use a 1/4 HSS drill bit then onto a 1/2 HSS drill bit, drill the top few millimeters only this is hardened, after that you should feel the drill "notching" through to the first disc tumbler, remove and swarf and disks with a pick you should be able to pull out all 6 disks and remove the small round bar in the lock barrel "which only drops when all disks are aligned", insert a screwdriver and rotate to position 2 and depress removal pin, now withdraw lock from housing.

Wittybebop
August 2008

look under ofrd focus ingnition switch on internet and you will see there has been alot of problems with them and it gets costly .....there is one repair I used on my sons 2001 focus ..drill out the key tumblers and it works fine now and won`t start unless you have the right key to it because of the coded key.........it will also show you how to take it out ...good luck
if you can`t find it let me know and I`ll help
ks4sy@bellsouth.net

bg
August 2008