TSB: 09-011/00

1995-98 Protege, 2000 MPV - DOOR KEY DIFFICULT TO INSERT and/or ROTATE - DOOR KEY CYLINDER FLAP BROKEN

NOTE: This bulletin replaces 09-013/99. Please update your records accordingly.

BULLETIN NOTE

• This bulletin supercedes 09-013/99. The previous APPLICABLE MODEL(S)/VINS range has been expanded/ptxt>

APPLICABLE MODELS

All 1995-98 Protege.

All 1999 Protege with VINs lower than JM1BJ22X0184885.

All 2000 MPV with VINs lower than JM3LW28GY0107320.

DESCRIPTION

REPAIR PROCEDURE

1. Verify customer concern.

• If key cannot be inserted completely and/or cylinder cannot be rotated, key cylinder requires disassembly and removal of obstruction. Proceed to Key Cylinder Disassembly Procedure below.

• If key cylinder flap is damaged and key cylinder operates properly, proceed to STEP 2.

Key Cylinder Disassembly Procedure

1. Remove key cylinder assembly from vehicle per the Workshop Manual.

   

2. Pry off key cylinder cap and remove flap assembly. Discard cap and flap.

• Discard cap and flap.

3. Remove clip, lever, spring washer and spring.

4. With the key inserted, remove the tumbler assembly.

   NOTE: If key cannot be inserted completely, it will be necessary to depress the exposed tumblers to remove the tumbler assembly.

5. On a clean work surface, remove each of the tumblers and place them in their specific sequence to insure that they will be correctly reinstalled in their original positions.

6. Inspect for and remove all pieces of the broken flap.

7. Reinsert tumblers into their original slots.

8. Insert key into tumbler assembly and verify all tumblers fit flush with the tumbler body

   NOTE: If tumblers do not fit flush with tumbler body, tumbler(s) are installed incorrectly and need to be placed in their correct position(s).

   

9. With key still in tumbler assembly, insert tumbler assembly into cylinder.

10. Using the key, turn tumbler assembly inside cylinder to until it seats completely into the cylinder and remove key.

    

    NOTE: Make sure lever is facing the correct direction.

2. Remove key cylinder assembly from vehicle.

3. Pry off key cylinder cap and remove flap assembly. Discard cap and flap.

4. Install new cap assembly.

5. Install key cylinder assembly.

6. Verify repair.

PARTS INFORMATION

NOTE: This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.