T4 (2001) Ignition Switch - help!

[Dynamike]

Hi there,

The ignition switch in our 2001 Caravelle died on us this weekend. Luckily, we were able to get home by hotwiring her. From previous posts in the forum it seemed a rather common issue. Since we need to replace it quickly we followed the instructions on here got the angled Philips screwdriver and went to a VW dealership on the way up from the coast and bought a genuine and expensive ($77) replacement switch (VWN6N0905865). Unfortunately, the screw-head was rounded off so we couldn't remove the original switch until we were back home an hour later.

And now the shock. The original ignition switch is different to the genuine one we bought (and is advertised online):


Since I can't see anything saying "VW" on the original one and the fact that the screw holding the switch had been tampered with is it possible that it had been replaced in the past? Is there a way to replace the original part even though there's no VW part number on it? What are my options? Looking for the cheapest way out (keeping in mind we just had an expensive copy of our original key made).

Thanks for you advise!
Cheers,
Mike

edit: It's not the ignition switch. see below

[Sunny43.5]

If you can still turn the ignition actually on and off you could consider a starter button , we bought a second van earlier this year which had one fitted . Howard

[Bug_racer]

What exactly is different ? Can you slide it into the original location and it works ? The part number you have supplied is a Polo one as well ! From memory (I dont work on t4s much anymore) The white one is the old design superceded to the new black one .

add :

Quick search reveals its the right part number so it should fit ? : OEM / Performance Parts for Audi, BMW, Mercedes Benz, Mini, Porsche & Volkswagen - ECS Tuning

[Dynamike]

Thanks Howard. Love the starter button idea but as you point out I'd need to be able to turn the ignition on, which unfortunately isn't the case. But you still helped me. By researching starter buttons for a T4 I came across this post How to fit a new ignition switch - VW T4 Forum - VW T5 Forum (hope crosslinking is allowed here). Looks like the guy there replaced the same switch I currently have with the switch I bought.

From the pictures above I think it's obvious they're different and even when I carefully tried it wouldn't go in all the way. But then again, it seems that the new switch is supposed to fit in there. Can somebody confirm whether I actually need another switch or am I just bit moronic and it should fit?




Edit: Thanks Bug_racer! You pretty much confirmed that it's supposed to fit. Looks like the previous owner may have gone with a non-genuine switch in the past which explains the different design. With that knowledge I try a bit harder tomorrow morning. As I said, I was rather careful not to break anything but maybe it just needed a good push for the last centimeter.

[Bug_racer]

Try putting the key in the ignition when fitting the switch .

[Dynamike]

Thanks, I couldn't wait until tomorrow so I just tried it. Turns out it's NOT the ignition switch.
I don't know what the little pin is called that's supposed to turn the ignition switch, but this is the culprit. It's totally loose, turns in any direction (horizontally as well as vertically) and isn't responsive to me turning the key.

Assuming I have to replace the ignition barrel now, are the following steps correct in moving forward?

1. Order a new ignition barrel: e.g. http://www.justkampersaustralia.com/...el-j13716.html
2. Drill holes into housing to release the ignition barrel as described here http://www.vwwatercooled.org.au/foru...rel-54138.html and here http://www.vwt4forum.co.uk/showthread.php?t=101518
3. Get a locksmith to either reprogram the immobiliser to accept the new keys or change the profile of the new barrel to accept the old keys
4. Done


And do I really need to replace the ignition barrel or is there another way out/around?
edit: Since it's only the pin at the back of the ingnition barrel that's broken I might be able to replace only the pin and skip the costly step 3. Will let you know how I go

Does that sound about right?

[Sunny43.5]

As a matter of interest if you need the key to be recoded I used our local Mr Minit shop at our local shopping centre and it took all of 60 seconds to do and he didn,t charge me , I went back the next day and gave the guy 20 bucks Local VW dealer wanted nearly 100 bucks and I would have to book the van in with them to do it . Howard

[Dynamike]

Thanks Howard, got a mobile locksmith who's quite competitive with his prices but Mr. Minit is probably even cheaper than that.

Update on the ignition barrel.
It's quite possible to replace the pin only and avoid all the fuss with two set of keys or recoding etc.
However, it seems that this is only possible with a genuine barrel so I couldn't use the one I bought from JustKampers. Good thing they allowed me to return the product.
I ordered a genuine one from Europarts for $125 now. Hopefully this will do it.