Bumping this thread.

After having issues with the pushbutton start needing to press three times to start, i came across this thread.

I saved the ignition so I thought I would give it a try. Short story, the ignition is now back in the truck and working perfectly.

Couple things to keep in mind:
1. If you use a bench grinder, you will need to remove all the burrs with a small file, from the wafers and the tumbler
2. You dont need all the brass wafers. I removed about two or three
3. The spring is for the "left key in the ignition bell" Dont lose it. I put mine back together correctly and the bell doesnt work. I think it may work in conjunction with one of the wafers I removed. So if you want the bell, make sure the key pushes the lever to activate the bell before you reinstall
4. There is a small round metal piece with a plastic insert that may fall out. This helps guide the key in and goes on the end of the tumbler in the round hole. Took me forever to figure that one out
5. Leave the last wafer in (retaining pin).

I really think this is a good option considering the cost of a new ignition. I still use the same key for ignition and doors. If you're like me, you probably have 4 or 5 spare keys lying around that never really worked unless you jiggled them in the ignition. If you file down the wafers with all the keys you have, they will all work.

Happy to answer any questions if anyone decides to take this on.

 

Just bought a 1999 Disco 1 SD a few weeks ago. It came with 3 keys, 2 standard keys (drivers door and ignition) and one for the passenger door that was re-keyed by the previous owner. My son selected the wrong key and put it into the ignition. Strangely enough, this key started the truck without issue, however the key is now stuck in the ignition. With the engine running, you can turn the key one click back to turn off the truck, but it only turns to that initial location and is stuck from turning any further. Power is still on the radio, interior lights, etc. so I have to make sure every thing off to prevent battery drain. No problem starting the truck with the current key situation but do need to get the key out so my son can drive it without concerns.

Question: Using the method described in the thread, after removing the key barrel, will I be able to easily turn the key to remove it?

Thanks.

 

I don't think it is that easy. The barrel pulls out through the back, so you wouldn't be able to pull it out with the key in it.

If it were me (disclaimer - I do stupid sh*t all the time) you can cut the key to take the barrel out. That's what I would do, but do this at your own risk. Another option is a good locksmith. You can take the entire switch out and take that to a locksmith to have them remove the key. This is the safest way.

 

Thanks humroot. Will pull the switch and take it to a lock smith.