Ignition Switch not popping up

[Tim O]

SAAB 9-5 Vector Sport Estate 1.9Tdi, 2008. 101000 miles

I'd been having problems, with increasing frequency of the car electrics not switching off when the key removed from the ignition barrel. Doors not unlocking, remote not working and so on. Misbehaving interior light and radio, etc. The car seems to believe there is still a key in the switch. It finally gave up the ghost and now the remotes don't work at all. Interior light stays on when doors closed and locked (flat battery  ). I need to fix this.

Wasn't sure if it was the ignition barrel itself or the switch below it it failing, so this morning started to investigate.

Removed the ignition barrel, which exposes the electrical switch below. Using a screwdriver I established that this switch moves up and down freely, and if turned (with a big bladed screwdriver), hey presto, remotes work, doors lock properly and so on. Which led me to the conclusion it's the ignition switch itself. Had a good look at it, and whilst all seems fine I finally understood that it's not popping up like it should. Hard to explain but there's a pin that runs up a ramp when the key is turned. When the key is removed this pin is supposed to slide sideways (towards the centre of the barrel) to allow the barrel to pop up.

However, it looks like the housing around this pin is sufficiently worn to stop the pin moving freely, so barrel no longer pops up, and subsequently the electric switch below not is being allowed to operate.

It would seem, therefore, that I need a new ignition switch. 

What are my options? I'm guessing new switch would come with keys, but then door locks would need changing? Immobiliser? Remote key fobs? Anyone else faced with this, and what did you do?

Help!!

[Geoff1951]

Hi Tim, the sticking ignition switch is not unknown. I had it on my 9-5.

There'll be more informed answers along later, but a possible answer is the lock needs lubricating to allow free movement of everything. And by lubricating I DON'T mean a squirt of WD40, GT85 or similar. You can get a tiny (about the size of your thumb) graphite spray that includes a nozzle that lubes the whole ignition switch. A much cruder method is liberally rubbing the key blade with a soft pencil and inserting it several times, but I'm not recommending this personally!

You'll have seen there are some expert experts on STT, no doubt whe your post gets seen you'll get some suggestions if it is more serious than I've suggested.

[Tim O]

Couple of photos of bottom of cylinder/barrel (never sure of correct name)

Image 1196 shows the position of the cross pin in the correct position with the key removed, and in the pop up position.

Image 1197 show the pin with key inserted and rotated.

When removing the key the pin should slide up a ramp, inwards towards the centre, as per photo 1196, but because of wear in the die cast parts, it sticks and doesn't slide, preventing the pop up movement. I've tried 'tidying' the ramp with a small swiss file but it hasn't really helped. The main problem is the bore the pin sits in has worn, so the pin is no longer a good fit and friction is causing it to stick.

Is it possible to take a replacement barrel apart and reset the mechanism (tumblers?) to suit my original key?