I’m trying to get the Disco 1 1996 Automatic road-ready for a long trip. Besides the overheating, which I hope will be fixed with new thermostat, the possible misfiring which I intend to first address with new distributer cap and the need to replace & install a new power steering fluid pump, I am worried about having to put key in ignition barrel, pull key slightly out of ignition barrel & then turn it to start car. I have looked mostly in vain for replacement ignition barrel/lock. Also I have only 1 key. Any suggestions? Disco is in Portland area at present. Thanks

 

The internal tumblers wear out the interior wall of the cylinder and they get jammed. It is a pretty common issue on the D1. You can buy an ignition barrel from a D2 which are much less expensive. You will lose the 'lock out' protection which means you will be able to remove the key from the ignition while the transmission is in ANY position.

https://lucky8llc.com/products/ignit...fe313cd6&_ss=r

As for your overheating, there are many many threads on this and other forums about this issue. I'd expect to replace the viscous fan clutch at a minimum. Given the age of the vehicle, the radiator is likely to need service (re-core) or replacement.

 

My friendly local locksmith made a copy for my key. That is one of the first things I do with a new vehicle.

The key mechanism is a bit complicated, with little position switches and levers, but it is not hard to figure out. It is designed so the key can only be removed if it is pushed in all the way. After you use it a while, you will develop a feel for it, so don't worry too much.

Like Walt mentioned, mine were worn out and made the key hard to turn. I opened up the key part and filed down or removed some of the brass pieces with the key in, so now it turns easy enough for my wife to use. Eventually, I might just be able to use a screwdriver, like my Grandpa did with the '36 Chev.

 

My ‘92 Suburban was so worn out you didn’t even need a screwdriver.