[PunisherXIII]

Hey Everyone! I recently posted about an issue I am having with the ignition on my Smart Car 451. Specifically; I ended up with the ignition on my Smart Car seized and the key will not turn. I tried absolutely everything mentioned in the forum's to get it to turn, but absolutely nothing works. I took it to Mercedes dealer and their solution was to remove and replace the entire shifts assembly to get the cylinder out! (It's a clamshell that you can seperate) this option will cost me a whopping $1900! No thanks. They are "not comfortable" drilling out the cylinder so I am planning to go at it DIY. Any suggestions or recommendations would be appreciated. I have enquired with local local local lock Smith's who told me to go to the dealer. I am desperate need of help here lol

 

[Shalmaneser64]

Get a used ignition module from a junk yard?

 

[PunisherXIII]

Get a used ignition module from a junk yard?

Absolutely an option but however resolving the issue going down that road is like replacing an entire wall of your house because the window is broken. If I replace the entire module, then I also have to have the vehicle key reprogrammed anyways. Not to mention the labour involved in replacing the module. I should mention I was able to have the dealer order a vin specific lock cylinder matching my keys so it's just a matter of replacing the cylinder. In order to put the new one in, I have to get the old one out but can get it out without turning the key - which is not possible..so Im.left with drilling it out. Anyone ever done it before?

 

[Shalmaneser64]

Should have said used ignition switch assy. Not the whole electronic system. Do you have the new cylinder? If so, you should be able to estimate what size drill bits you need to drill out the old one.

 

[PunisherXIII]

Yeah I have the new one. In terms of drilling out the old one what part of the cylinder are you actually drilling out? More specifically - how much? I suppose enough to allow the cylinder to turn? So slowly increasing the size of bit? Also how deep do I go ?

 

[Miss Mercedes]

Here's how to remove the ignition cylinder:

451 Ignition Barrel Removal | Evilution

www.evilution.co.uk

All you really need to do is drill it out enough that the key turns. Don't drill too deep or else you risk damaging other parts. I'd probably recommend doing it with the battery disconnected.

Had to do a similar job with my Ford E-350 Power Stroke a couple of weeks ago. Not fun.

 

[PunisherXIII]

Here's how to remove the ignition cylinder:

451 Ignition Barrel Removal | Evilution

www.evilution.co.uk

All you really need to do is drill it out enough that the key turns. Don't drill too deep or else you risk damaging other parts. I'd probably recommend doing it with the battery disconnected.

Had to do a similar job with my Ford E-350 Power Stroke a couple of weeks ago. Not fun.

I was thinking I'll put some electrical tape as a guide so I know where to stop depth. I assume I start with a smaller bit and work my way up?

 

[gtdump]

Were it my car, I'd probably remove the cylinder and fabricate a bit to work the mechanism. Without the fob it should be disabled, so the key itself is then really only needed for the doors, no?
I've condiered a number of times of removing the key from one of my fobs and 3D printing a knob to glue to it and just leave it in the car as if it were permanent, like this:

Smart fortwo 450 Ignition Knob by Rioryan

Note: Only works on 450 models - not models with proximity-based immobilizers. I got this idea from an aluminum product sold in the UK. Yank your ignition key out of the key fob and stick it in this knob. It can now stay in the car, and most folks won't even realize the key is in the ignition...

www.thingiverse.com

 

[Miss Mercedes]

I was thinking I'll put some electrical tape as a guide so I know where to stop depth. I assume I start with a smaller bit and work my way up?

I went in with the big guns from the start. lol

Granted, an old Ford E-Series has a thick ignition cylinder and no chip key to worry about. In my case, the van was stolen from me and the original ignition was hammered out, so I had to remove the guts to get a proper ignition switch back in.

 

[PunisherXIII]

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!

 

[vadsoom]

Just a thought....

Smarts have electronic starting, meaning that the start and run signals from the key tumbler assembly are low current. If the key tumbler is shot anyway, a simple button could be added to start and stop the car. Of course, the fob would still need to be placed near the ignition to have enough signal to reach the immobilizer to allow the car to start. Kane has instructions here (you will need a subscription, please support Evilution):

Starter Button | Evilution

www.evilution.co.uk

 

[Shalmaneser64]

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!

Thanks for the update and info. I was not aware that the key fob communicated when starting. Guess I wasn't paying attention in class...

 

[smark]

Do not drill out anything. Bad advice. Have a lock smith take a look at it. The tumbler is sink to the key electronic.

 

[apgrenus]

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!

This literally saved my bacon and we were able to get the car home. Do you know where you got the replacement lock cylinder that matched your key?

 

[merellegolf]

Hey Everyone! I recently posted about an issue I am having with the ignition on my Smart Car 451. Specifically; I ended up with the ignition on my Smart Car seized and the key will not turn. I tried absolutely everything mentioned in the forum's to get it to turn, but absolutely nothing works. I took it to Mercedes dealer and their solution was to remove and replace the entire shifts assembly to get the cylinder out! (It's a clamshell that you can seperate) this option will cost me a whopping $1900! No thanks. They are "not comfortable" drilling out the cylinder so I am planning to go at it DIY. Any suggestions or recommendations would be appreciated. I have enquired with local local local lock Smith's who told me to go to the dealer. I am desperate need of help here lol

This literally saved my bacon and we were able to get the car home. Do you know where you got the replacement lock cylinder that matched your key?

This literally saved my bacon and we were able to get the car home. Do you know where you got the replacement lock cylinder that matched your key?

This literally saved my bacon and we were able to get the car home. Do you know where you got the replacement lock cylinder that matched your key?

Hey first need say thank you!! because for your post was how can I fix my 2014 Smart fortwo, let me explain that, after few days I'm found your update of this post so i work on
it, after got the cylinder lock in my hands I look on it and see the black plastic cover (need take care to take out with out damage) so I take out this cover and see other slot by the slot key , so I'm try with straight pick into the slot and lube inside with PB Blaster at the same time play with the key and after two or three seconds the key finally turn try several tums lock and unlock the cylinder and when I see working okay I'm remove the key put back the plastic cover and install back the cylinder lock and my car start working properly again, thank you for this post I'm fix my car for free my self, if this way work for someone else arm yourself with patience and with care you will be able to repair your car in the same way that I did.
Thank you PunisherXIII for yor post.

 

[Kerplunk2310]

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!

Hi there Im having a hard time with my smart for two the wife had lost the only key we had for it and I had sent the ECU and s.a.m unit off to sos diagnostics in Oregon to have new keys programmed but in the mean time I needed to move the car so it didn't get towed so to unlock the wheel and the gear shifter i at first intended to drill out the tumbler but like you realized it would be easier to just remove it my problem is I got the s.a.m , ECU, and new keys back from sos diagnostics I've tried just setting the key/fob in the ignition barrel but won't start and it's still flashing the key symbol sos diagnostics assured me that they tested my parts and new keys in they're shop car so that leads me to believe the problem is on my end is there some special way you gotta position the key/fob to get it to demobilize? I tried to send you a message it wouldn't let me for some weird reason could you email me @ [email protected] or text me @ 360-951-1584 my names Byron thank you