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Discussion Starter · #1 ·
Hey Everyone; this community has been a long time resource for my challenges with my 2009 Smart Car For Two. For about 4 days now I've been dealing with an anomaly that has me completly stumped. My ignition key randomly will not turn. It feels like the if orion wafers are jammed. The key will turn half way to first ignition point (1) but no further. Here is what I have done to attempt to remedy:
1) Lubricated the ignition.
2) Heated the ignition with a hair dryer for a brief period. (Enough time that I'm convinced it's not frozen)
3) Sprayed rubbing alcohol in the lock.
4) Ensured the car battery was charged.
5) New remote batteries.
6) Tried both keys.
7) Tried tapping the ignition lightly.
8) Tried pressing the yellow tab under the console.
9) Tried rocking the car back and forth.

When I lubricated the ignition it seemed to allow the key to turn slightly further but I cant say with absolute certainty. I don't see anything lodged in the lock.

Just before this occurred I had a flat tire and had a tow truck flatbed the smart about 3 km to my work. I changed the tire the next day at work and drove home about 100 kms without any issues. Got home and parked it. 2 days later I changed the tire after plugging the other one and went to start it and the key would not turn. I'm going crazy here!! I hope someone can help!
 

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You probably got something jam down inside the cylinder lock. Why don’t you pull the cylinder lock, and run it by a lock smith. One of the pins in side the Ignition log has failed, or dislodged. There are small spring in there. You can’t even buy a new lock cylinder. #9 part. cause it a thief defiant feature.

65506
 

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Discussion Starter · #3 ·
That may be my only option. Anyone have any information on how to pull it apart beside just "doing" it?
 

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Hey Everyone; this community has been a long time resource for my challenges with my 2009 Smart Car For Two. For about 4 days now I've been dealing with an anomaly that has me completly stumped. My ignition key randomly will not turn.
I had this happen to me a couple of weeks ago. I was driving for a company in my Smart and was at a customers house. Went out to the car, put the key it and it would not turn. It did this to me once before while at a Walmart a while back. In both instances I got the key to turn by force (not enough force that you know will break it) slowly, incrementally applying more force and backing off if you feel the force may break it and trying again. (repeatedly) (if you are the type of person who strips bolts with a wrench or ratchet - do not do this) After it goes free by force it stays free for the next event of this that may come in a year. This is very disconcerting when it happens because you are 'dead in the water' and if you are in someone's driveway you will not be able to roll it out of the way because it is jammed in park. (though a towing facility may be able to lift the car to remove it) To this day with this car if I pull in someone's driveway and blocking someone I will put in neutral and just turn the ignition off and put on the hand brake, leave the key in if it looks safe from theft or park on the street. To clean when I get it home I use electrical contact cleaner with the tiny hose on the spray button putting the hose in the keyhole and CRC 2-26 electrical lubricant.

These cars do this so if yours hasn't, I would still lubricate the switch once in a while
 

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Graphite powder key lock lubricant...

You got to turn it to the ON position to remove it.

Sent from my moto g(7) power using Tapatalk
 

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Discussion Starter · #7 ·
Graphite powder key lock lubricant...

You got to turn it to the ON position to remove it.

Sent from my moto g(7) power using Tapatalk
Tried that already with no luck. I'm.at the stage where the dealer wants to replace the whole shift module assembly - I suggested drilling it out but they are not comfortable doing it so I got a new cylinder specific to my key. I'm now going to drill out the old one - any advice?
 

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Did you get the point where you disconnect the transponder interface? Before drilling I would disconnect it (1).

Then try turning key again...


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Discussion Starter · #9 ·
I haven't started yet. I plan to disconnect the transponder before drilling as well. Basically going to remove the console disconnect battery, and remove electronic transponder and then drill.
 

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I haven't started yet. I plan to disconnect the transponder before drilling as well. Basically going to remove the console disconnect battery, and remove electronic transponder and then drill.
I just went out to my 2014 Electric Drive and it is doing the same thing. I will watch this thread to see if you have success! In the mean time, I will probably start to disassemble the shifter assembly cover to again access to the ignition lock cylinder. Keep us posted with your progress and I will do the same.
 

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Discussion Starter · #11 ·
Will do. I did manage to purchase a new lock cylinder from the dealer that is specific to my vin for $180 - this will prevent me from having to get new keys and essentially just replace the cylinder itself. At this point the dealer wanted to replace the entire shift module and quoted me $1900!!! No way that is happening. So once the new lock cylinder comes in, I'm going to drill out the old one very carefully and then slip the new one on. I plan to do this Monday so when I'm done and hopefully successful, I will definitely be posting a detailed summary of the repair to help others. There seems to be very little I formation on resolution of this problem.
 

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I had the same problem yesterday. I used my small air compressor to blow air down into the lock cylinder. I saw some very small particulate come out, and when I tried the key it worked fine. I would try the compressed air and see if it will help.
 

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Discussion Starter · #13 ·
Glad that you resolved your issue. I've tried my compressor, graphite lubricant and just about every "easy" solution with abolutly no luck. Definitely at the point where I'm drilling that cylinder out sadly. I believe it is probably seized entirely.
 

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Discussion Starter · #14 ·
Well everyone; just wanted to provide an update to anyone that ventures into this post searching for a solution to this problem. Basically I was able to remove the old lock cylinder WITHOUT drilling it by sheer luck. Here is how I did it:

1) Remove the entire shifter cover assembly. (You can find instructions on Evolutions website on how to do that)
2) Remove the lock security assembly. It's plugged in and it's the plastic portion that sits around the lock cylinder itself.( When functioning, it senses your key fob and is programmed to your fob.)
3) With this removed, you can attempt to remove the lock cylinder by depressing the tab at the base, however this usually can't be pressed in until you are able to turn the key. Thus the cyclic issue of not being able to remove th cylinder. What I did here was originally plan to drill out the cylinder. When beginning that, I noticed that the plastic around the cylinder seperated into two sections that split in half. All I did was gently used a flathead screwdriver and pried the two halves apart while pulling up on the cylinder and eventually got it free. Be careful though because you can save the cylinder housing. Once you get the old one out, you can slip the new one in without issue.

Note: I didn't have the cylinder on hand, so I was forced to improve when driving the car. Of you want to be able to drive the care by using a screwdriver then this is what you can do:

  • Once the old cylinder is removed, reconnect the security assembly and plug it back in.
  • Place the key fob ON TOP of the cylinder housing hole. (it will not sense the key anywhere else)
  • Turn the ignition using a flathead screwdriver.

Note: Once the car starts you can set the fob aside. Your good to go.

I'm going to write up a tutorial for this repair because I've never found a suitable solution in any forums I scoured and I'm positive others will want help on this. Until then; just message me and I can assist you.

Glad to finally have the issue resolved!
 
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