Ignition barrel failure/replacement

[mjonesy1]

Hi all, my Bongo is stuck in ACC mode with all the usual lights on with the key in any position and even when the key is removed. Bongo won't start either. Pretty sure it's the ignition barrel that needs replacement, does anybody know where i can source a replacement and have experience of replacement? Thanks, Martyn

[Gasy]

Have you checked / oiled the cable from gear stick to ignition
The one like a bike brake cable
Have you tried working gear stick 1st to park loads of times
Can be a stuck cable

[JoeC]

Also put a drop of light oil on the ignition key and put this in/out of the barrel a few times, As a bit of preventative maintenance, do this for all the key locks.

[Simon Jones]

It sounds like the barrel itself is ok as it appears to turn and allow the key to be removed, but the rotary switch on the end of it may be disconnected or no longer engaging with end of the barrel. I think it will need to be removed for inspection to see exactly what the problem is.

[mjonesy1]

Thanks for all the advice, is there a step by step guide to removing the steering wheel and cowling so I can remove the ignition barrel and switch?

Thanks
Martyn

[Northern Bongolow]

http://lushprojects.com/bongopartsmk2/c ... mgno=.html.

http://lushprojects.com/bongopartsmk2/c ... mgno=.html.

http://lushprojects.com/bongopartsmk2/c ... mgno=.html.

http://lushprojects.com/bongopartsmk2/c ... mgno=.html

[mjonesy1]

Thanks fro the diagrams - does anyone have any fist hand experience/tips of removing the steering wheel cover?

[mjonesy1]

By way of an update I've found the fault - where the mechanical ignition lock mates to the electrical ignition switch the metal spindle has broken on the key switch side.

There is no way of fixing it so it will need a replacement lock. Unfortunately the unit is bolted on with shear bolts so they will have to be ground off to make way for the replacement unit - as long as I can find one!

In the meantime I can start the Bongo now, I've disconnected the ignition switch and I can turn that manually to start the engine then, use the key to locked the steering and gear lever and away we go.

No the best but it will work for a short time, I have traced the switch connections and may make a more semi permanent solution with proper switches.

Will keep you updated.

[Simon Jones]

Thanks for the PM. Glad you've got to the bottom of it. You can buy second hand complete sets of barrels for all the locks so you replace them all and use the new key. In your case it may work out cheaper/less hassle to see if Mazda can send you a replacement ignition barrel coded to match your key. Let us know how you get on.

[mjonesy1]

A late final update, all fixed!

A replacement barrel was ordered and fixed in about an hour. Process:

Disconnect battery for 30 minutes to remove any charge from the air bag
Remove the instrument panel cover to improve access
Remove the airbag (two bolts accessible from the side, rear of the airbag)
Tippex the steering wheel and column and mark to align when replacing
Remove the steering wheel (don't remove the nut until the steering wheel is loose, prevents injury!)
Use a hammer and centre punch to remove the old shear bolts
Disconnect all wring looms and the handbrake cable from the ignition barrel
Remove the ignition barrel
Add the new barrel - align with steering lock bolt under the column
Tighten the shear bolts but DO NOT SHEAR
Reconnect the wiring looms and handbrake cable
Refit the steering wheel to the correct alignment
Test
If all ok then tighten the bolts so they shear and replace everything you removed to get this far.

Good luck!

[James Hill]

Tried to purchase second hand parts but diameter too small need to find a 4cm diameter unit please send recommended parts suppliers

[g8dhe]

Have you tried BongoSpares ?
https://www.bongospares.co.uk/shop/elec ... per-stalk/#