How do you install an ignition switch in a Chrysler town and country mini van?

Answer 1

I just did this on a 2000 T&C last month.

1. ALWAYS disconnect the battery Negative cable.

2. Remove the screws (#2 Phillips) from the lower knee protector. There's 2 behind the parking brake handle, and another under the dash side vent cover (just pry it off), and one below it. Last ones (2) are on the bottom edge of the panel. The rest of the panel (the right side) is held in with a friction clip, so gently pry the panel out. It can hang by the parking brake release cable assy, just be gentle with it.

3. Take out the 3 steering column cover screws (#2 Phillips) from underneath the column and remove the covers.

4. Put the key switch in the RUN position and press the retainer tab (Under the column, near the left end of the key switch housing there's a hole to access the tab) with a screwdriver and remove the key cylinder. (It won't come out in anything other than the RUN position.)

5. There's a tamper-proof #10 TORX screw holding the ignition switch in. (That's a #10 TORX bit with a hole in the center.) I had the tamper-proof TORX bit but had no luck getting it to remove that screw. I used a Dremel tool with a diamond cutting wheel (the darn screw is hardened - a hacksaw did nothing) and cut a slot in the screw head. Came out easy enough that way with a flat blade screwdriver. (I replaced the screw with a 4MM Phillips head screw approx 1/2" long from the hardware store.)

6. Near the right end of the ignition switch there's another access hole with a tab that must be pushed to release the ignition switch. I had to pry the switch out carefully. It's in there tight!

7. Now disconnect the electrical connector and it's out! Watch out for the actuator shaft (a rod) that goes to the key switch, so it doesn't fall out. (If it does, just put it back in when you put the new switch in. It will only fit one way.)

8. Make sure the replacement switch is in exactly the same position as the old one (RUN position) and put it all back together the reverse way it all came apart. The new switch fits tight, but it will go in so it is just like the old one was. The screw will make sure it is fully seated.

9. The key switch only fits one way, so align the protrusions with the grooves and it will slide right in. Turn the key from the RUN position to the lock position when done. Reconnect the battery and try it before putting all the covers back on. (It's almost normal to accidentally actuate the 4way hazard switch as you reassemble the steering column shroud because it's a clumsy thing to get the shrouds fitted properly back together.)