Here's a copy of a service bulletin on your
problem.
I'll bet the dealer says $300 for parts and 2 hrs labor.:screwy:
Ignition Key - Will Not Turn And/Or Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT:
Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS:
1997 - 2000 (NS) Town & Country/Caravan/Voyager
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:
1. Cannot turn the ignition key when attempting to start vehicle, this
condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED:
Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or
IL-ECM-100
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:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE
SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned
on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to
rotate the key to the start position and then the accessory position.
4. 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.
5. 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.
6. 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.
7. 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.
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.
9. 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.
10. 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).
11. 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.
12. 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.
13. 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.
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.
15. 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.
16. 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.
17. 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.
18. If the key turns, repeat steps 16 and 17 ten times. If the key
continues to rotate smoothly the repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall
freely away from the driver when it is brought up into the Park
position.
2. If the shift lever does not seat fully up and away from the driver
the column will not allow the key to be removed.
3. If binding of the shift lever is discovered, adjust the transmission
shift cable using the procedure outlined on page 21-114 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No.
81-370-0005).
Before you attempt to remove the ignition you may want to try tapping the end of the key gently with a hammer as this is a common chrysler, dodge problem. Usually that will cause the key to go in far enough and release the ignition to turn. I use it regularly with my 99 town and country. It does not fix the problem permanently but at least saves you the effort of having to change the ignition lock.
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