Spent some kwality time yesterday trying to remove the ignition tumbler in my '85 300d. Now I know why this job isn't high on anyone's faves list.

I looked at a couple of YT videos, at old posts on here, and yes I looked at the FSM.

Even Mercedes describes the wire insert needed to free the tumbler as a "self-made tool." I made two using kitchen spears, and filed the ends off to 70 degrees. They are pretty much as thick stock as will fit through the tiny opening. Neither worked, they bend too easily.

Does anyone else have a better idea for what to use, to fabricate the tool? I looked at my coathanger stock and even the lightest ones are too thick rod to work.

One video suggests baling wire. Not sure if that is an easily found commodity around here.

__________________


Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

I have had very good sucess using the large size paper clip. Bend it so that you get the longest straight part sticking out and use the rest of it for holding. It works great.

__________________
Junqueyardjim
Christianity, if false, is of no importance, and if true, of infinite importance. The only thing it cannot be is moderately important. C.S. Lewis



1983 Mercedes W123 240D 4 Speed 285,000 on the road with a 617 turbo, beautiful butter yellow, license plate # 83 240D INDIANA

2003 Jaguar Type X, AWD. beautiful, good mileage,
Mom's car, but I won't let her drive it!

I've used a drill bit and an allen key, both of the required size (2mm ??) and they did the trick on a 124 car.

__________________
Respectfully,
/s/
M. Dillon
'87 124.193 (300TD) "White Whale", ~392k miles, 3.5l IP fitted
'95 124.131 (E300) "Sapphire", 380k miles
'73 Balboa 20 "Sanctification"
Charleston SC

Piano wire, that you can buy at a good ole fashioned hardware store, works great. Think I used some that was .088", but unsure of size now.

I just use a Paper Clip, go to position #2 and stick it in the hole and unscrew the black collar. Used it 3 time here at the house and several times at PNP. (if the key was there).

Been a while since I did this job, could be position #1 with the key.


Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

The smallest standard screwdriver in the Radio Shack Screwdriver kit. It's the right size and the screwdriver tip allows you to wiggle it in where a paperclip might jam.

Be careful with the jewelers screwdriver. I broke one off in the hole. Luckily I was able to fish it out.

"Jumbo" paper clip, with the longest leg bent straight, does it the best.

Remember that the amount of force needed is not very great, you are trying to push a small spring loaded tab down into the body of the lock cylinder. This tab stops the black collar from spinning.

It is one of those things that you cannot easily describe, but once you do it you realize how simple it is.

__________________
The OM 642/722.9 powered family
Still going strong
2014 ML350 Bluetec (wife's DD)
2013 E350 Bluetec (my DD)

both my kids cars went to junkyard in 2023
2008 ML320 CDI (Older son’s DD) fatal transmission failure, water soaked/fried rear SAM, numerous other issues, just too far gone to save (165k miles)
2008 E320 Bluetec (Younger son's DD) injector failed open and diluted oil with diesel, spun main bearings (240k miles)

1998 E300DT sold to TimFreeh
1987 300TD sold to vstech

I just did one on my '83 240D. The FSM calls for the release wire to be .040 in diameter. I miked a large paper clip, and it was exactly the correct diameter. Worked like a jewel no problem. The coat hanger, that worked on other Mercedes' didn't fit on this. It's just too big! It helps to bevel the edge a little.

__________________
Rebe

If you get desperate, Mercedesource dot com has a bunch of tools for this:

https://**************.com/store/search?keys=ignition%20cylinder

I used some generic Bailing Wire and it did indeed bend; I have no large Paper Clips.
What I had to do to get it to work was grip only 1/4" at a time of the Wire with an 90 degree angled Needle Nose Pliers.
I shoved in 1/4 Inch at atime and took another 1/4 inch bite and shove that in until the Tumbler was loose.

The other thing I found out is look with a good strong Flashlight. As I rotated the Tumbler what I first thought was a hole was actually a Roll Pin and I had to rotate further to find the actual hole.

Attached Thumbnails

 

__________________
84 300D, 82 Volvo 244Gl Diesel

Fed-Ex has a supply of large and small Paper Clips in their copy stores between the Copy machines.


Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Thanks everyone for the ideas. I raided the mailroom in my office building and scored some offbeat clips. I do see the big difference in tensile strength (hope that is the right term) between these and the cooking spears.

Hope to get back to this fast as I am at the point of leaving the key in the tumbler, barely cracked out of the off position, as when I remove it, it's very hard to turn the tumbler to disengage the lock.

__________________


Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

I thought I had a Lock Tumbler Issue and it turned out the Steering Colum Lock was broken in 2 Places.

Since I wanted an new Ignition Switch I bought the Steering Colum Lock as an assembly and it has the Switch, Steering Colum Lock and Vacuum Valve.
The Ignition Switch had made in West Germany on it.

My Lockt Tumbler turned out to be OK. I threw the Lock Tumbler into My Ultrasonic Cleaner and a lot of sort of gray dust cam out of it.

__________________
84 300D, 82 Volvo 244Gl Diesel