Mazda Ignition Fix

I got a call recently from a customer complaining that his vehicle's key got stuck in the ignition switch. The vehicle was a 90 Mazda 929. According to the customer, the key seemed to get stuck once he was turning it to turn the car off and was not able to remove it after that. The customer also informed me that he had a locksmith technician he knew tried working on it, but without success. Once I got to the job site, I ran a quick inspection and saw that even thou the key was stuck in the ignition, I was still able to turn it to start the car and to the "accessory" position as well. When I looked closely after shutting the car off while I was doing the inspection, I noticed that the key would not turn all  the way to the "off" position. I then realize that this might be the problem, and if I could align it properly and get it all the way to the "off" position, the key will come out. In order to do that, I had to take apart the column shroud in order to see what causes the key to not turn all the way.

Once I got the steering column trim, I noticed there was a cable coming out from the top of the lock that seemingly will move forward and backward as the shift lever is changed from the D to R position. The cable however, seem to function properly, so that was eliminated as a cause to the issue. The next thought I had was maybe there is a bent or broken wafer inside the switch that will prevent the key from being removed. At that moment i realized I didn't have any choice and removed the ignition switch. However, when I took it out and inspected it, it seem to work fine, but once it was installed again, it seem to have the same problem. I then went further to remove the shift lever and I noticed that there was a component there that prevented from the the cylinder lock to go all the way to the "off" position. When I looked closer, I noticed it was a plunger that has an impression mark on it where it would stick to the lock. In order to solve this, I gently file the mark on the plunger piece and re-installed everything the way it was and the key finally was removed without any issues.

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