2000 Dodge Caravan ignition

Tiny
MARKB1125
  • MEMBER
  • 2000 DODGE CARAVAN
  • 6 CYL
  • 2WD
  • AUTOMATIC
  • 132,000 MILES
Key will not turn
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Wednesday, June 10th, 2009 AT 7:34 PM

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Tiny
BMRFIXIT
  • EXPERT
I would recommend a lock smith its your best bet if possible

good luck

TECHNICAL SERVICE BULLETIN

IGNITION KEY WILL NOT TURN &/OR CANNOT BE REMOVED
TECHNICAL SERVICE BULLETIN
Reference Number(s): 23-23-00, Date of Issue: June 30, 2000

Related Ref Number(s): 23-23-00
ARTICLE BEGINNING
IGNITION KEY WILL NOT TURN AND/OR CANNOT BE REMOVED
Model(s): 1997-2000 Chrysler (NS) Town & Country; 1997-2000 Dodge (NS) Caravan; 1997-2000 Plymouth (NS) Voyager
Group: Body
Bulletin No: 23-23-00
Effective Date: June 30, 2000
OVERVIEW
This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION
Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED
PARTS INFORMATION
Qty. Part NumberDescription
AR (1)04778115Key
AR (1)05003843ABCylinder, Ignition Lock
AR (1)04690523Assembly, Ignition Switch and Lock Housing

EQUIPMENT POSSIBLY REQUIRED
Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM100
T-27 Torx Bit
T-25 Torx Bit
T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS / REPAIR PROCEDURE
This repair is compatible with DaimlerChrysler's Mobile Service Program and does not require hoists or other full service facility special equipment.
SYMPTOM/CONDITION ONE
Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
Disconnect the negative battery cable.
Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position.
If the key does not turn, remove the key from the lock cylinder and rotate it 180 . Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key.
NOTE:Use the key code on the vehicle invoice to correctly cut the new key. Key codes are also available using the D.I.A.L. System, main menu option 13. Do not use a key duplicator to make the new key.

Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position.
If the key turns, remove the key from the lock cylinder and turn it over 180 and reinsert the key into the lock cylinder. Attempt to rotate the key.
If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE LOCK CYLINDER.
Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position.
If the key turns, remove the key from the lock cylinder and turn it over 180 and reinsert the key into the lock cylinder. Attempt to rotate the key.
If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
NOTE:Skip steps 13 and 14 of the service manual removal procedure so the ignition lock housing and ignition switch are removed as an assembly.

Install a new ignition lock housing and ignition switch assembly, P/N 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
NOTE:Prior to performing step 2 of the service manual lock housing installation procedure, install then remove the two lock cylinder housing mounting screws into the lock housing mounting holes to create the threads in the holes. Failure to create the mounting hole threads prior to installation to the steering column may cause misalignment of the lock housing to steering column and damage/binding of steering column may result. Steps 5 and 6 of the service manual installation procedure for the lock housing are not necessary for this TSB procedure. When performing step 9 of the service manual procedure use the new lock cylinder that was built in step 9 of the SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE of this bulletin.

Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position.
If the key turns, remove the key from the lock cylinder and turn it over 180 and reinsert the key into the lock cylinder. Attempt to rotate the key.
If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete.
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Wednesday, June 10th, 2009 AT 8:07 PM

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