Tonight I stopped at a Shell to get a drink and chips. As I climbed back into my Volvo, I looked at the key and noticed that only half of it was there. The other half, to my chagrin, was still stuck in the ignition switch. And me being 25 miles from home.

So my key broke off in the ignition. Now I need to know how to replace the stupid thing. Anybody got any pointers on how to approach this? At the Shell station, I borrowed their phillips screwdrive and removed the steering wheel housing, then tried to remove that big black structural brace, but after taking out 7 screws, it still wouldn't budge. And the switch was still fortified like a Norman Keep.

I'm in a quandry. Please, please help.

kevin

Its not too hard to take the whole lock assembly off. You need a screwdriver and a pair of vicegrips. You do have to get the crossmember off. I think there are at least 6 phillips head screws underneath and maybe a couple under the trim on the dash(can't remember exactly). Then you have to slide the crossmebmember back to get it off because it is locked into white plastic guides on the ignition lock. Once thats out of the way take the shear head bolts off with the vice grips as well as the 2 phillips head screws you uncovered by removing the crossmember. You should be able to take the lock off the column at this point.
Then you can take the ignition switch off the lock by removing 2 flathead screws, and start the car by turning the switch with a flathead screwdriver.

Just saw your post, so I hope things are underway towards repair.

Wondered if, since Volvo keys,if original, are steel, a gawdawful powerful magnet could pull out the remainder piece?

Good Luck,

Bob

:>)

Get a stiff piece of thin wire, and roughen the sides with a file. Fit into lock and try and snag the side of the key. Also try making a short 90 deg bend at the end and slide into lock and try and snag end of key.

You might be able to get it out using a small pair of foreceps you can get from a hoby store.

Even though the key was broken in the ignition, you may have still been able to get home by inserting the remnant (or a screwdriver) in the lock and turning.
--
1980 245 Canadian B21A with SU carb and M46 trans

Tried that, it won't turn. And I was able to get home (25 miles away from my car) by calling my wife, who graciously packed up the kids into our 95 850 at 9:30 pm and came and picked up my sad ass.

I just called 2 locksmiths in Lexington. The first didn't want to do it, and the second said it will cost AT LEAST $65, and probably more depending on how hard it is, because (and I quote) "Volvos are really hard to get the keys out of the ignition".

I also called the dealer and inquired as to how much it would be to have them replace the key switch if I towed it in. The answer was a shocking $375. That's $212 for the switch, and I guess $163 in labor. Interesting that a 240 key switch costs $212 when, in contrast, an 88 Chevy truck key cost me $15 2 years ago.

I won't pay these prices. I'll extract it myself. Wish me luck.


kevin

Hi Kevin:
I'll second what Rob (Aye Roll) says. I did the same thing and a locksmith came and pulled it out in no time. Charged $50 for the house call. Might even be able to make you a key on the spot, although I agree with Rob that the dealer option for the key is a good one--especially since you are as far from home as you are.

Repost when you get this taken care of so we know what happened...

Mike

PS: So how did you get access to a computer to post to the board?
--
Mike Brown Greenville, NC 1996 965 113K 1994 940 135K 1986 244 137K

Do you have a spare key at home or anywhere else? IF so, I would call a locksmith to simply pick out the bit of old key in there, and then just go have another copy made.
If you DO NOT have another key, don't panic. Still call the locksmith, you still need that piece out of there. But your Volvo dealer parts department can MAKE YOU a new key on the spot. They have key codes for all the 240s and 740s, all the models using the plain steel keys.
They look up your VIN, and punch out a new key from the codes onto a new key blank. Works great though the new key will be a bit notchy till it wears in a little. It'll help if you round the edges of their work a little bit.

I only recommend a locksmith because I've seen a lot of people screw up the ignition lock trying to get a broken key out using the wrong tools. A decent locksmith will have all sorts of tiny picks and tweezers just for doing this, and ought to charge under $50 for the service. If you have AAA, it may be free or cheaper anyway. Tell him not to worry about the key, they'll charge a lot more than the $15 the dealer gets for it.

A friend broke her key off in the ignition of her 88 245 last year and it was only $35 to remove the broken piece, then we got a new key punched out, no problem.
GOOD LUCK!!
--
Rob Bareiss, New London CT ::: '87 244DL/M47- 234K, '82 245T/M46-182K, '89 244DL/AW70- 212K Not too distant past: 86 244DL 215K, 87 244DL 239K, 88 744GLE 233K, 88 244GL 147K, 91 244 183K

Had this happen in another car once.. I used super glue and carefully glued the stub end of the key to the part left in the ignition but be warned it can ooze out and get stuck on the switch so be careful...By the way there is a pic and post somewhere on the board about replacing the switch,, its a job from what I understand..
--
Max..1989 244 DL 5 Spd., Bilstein HD, Turbo Swaybars, Poly Bushings all round, Turbo Wheels, Black leather interior, Electric mirrors, LED dash and gauge lights.

Try using a thin, narrow coping saw blade to pull the key remnants out.