Ford Focus Mk1 ignition barrel replacement

Method 1: Full disassembly (for drilling)

Using an 8 mm socket, remove the four screws from the trim panel under the steering column and remove it.

Undo the three screws on the lower column shroud using a Torx key.

Release the two clips of the upper shroud using a thin flat-blade screwdriver.

If the lower shroud needs to be fully removed, simply lift the upper shroud upwards.

If the lock failed away from home and the steering is locked, you will need to knock out the bottom cover of the ignition switch and remove the spring holding the locking pin to unlock it.

View of the steering lock pin from below.

To remove the steering wheel, turn it 90 degrees. Using a 5.5 mm socket, undo the two screws on the back of the steering wheel spokes holding the airbag unit.

Carefully pull back the airbag unit. Disconnect the electrical connectors. Do not pull on the wires.

Undo the central steering wheel retaining bolt using a 24 mm socket. It is recommended to mark the position of the wheel relative to the shaft with a marker pen.

Remove the steering wheel from the splines by pulling it towards you.

The clock spring casing (squib) must be secured with electrical tape to prevent it from rotating, otherwise the ribbon cable may snap during reassembly.

Remove the centring sleeve (if fitted) using a screwdriver.

Disconnect the ignition switch contact group, which is held in place by two clips.

To remove the column stalks, press the clips on top of them, disconnect the wiring plugs, and move the stalks aside.

Undo the screw securing the immobiliser (PATS) antenna to the back of the lock using a Torx key. Carefully remove the antenna ring from the barrel housing.

Remove the clock spring housing: pry back the two clips and disconnect the plug.

This is how the steering column looks when prepared for work.

Proceeding to drilling. This method is only necessary if the key is lost or will not turn. Drilling the retaining pin is not recommended unless absolutely necessary to avoid damaging the housing.

The barrel is held in place by a retaining pin which only retracts when the key is turned to position I.

Drilling guide: mark a point on a line drawn through the centre of the lock perpendicular to the keyway, approximately 3 mm below the keyway itself. Drill a hole about 4 mm deep using a 3 mm bit. Then drill in 38 mm using a 10 mm bit (drilling out the internals). Remove the debris, turn the mechanism to position I with a screwdriver, press the retaining pin, and extract the remains of the barrel.

Installation of the new barrel is the reverse of removal.

Method 2: Quick replacement (without removing the steering wheel)

This method works if the key still turns. Remove the plastic steering column shrouds (see previous steps) to access the lock housing.

Locate the release pin hole on the lock housing (see photo). Insert the key and turn it to position I (ACC). If the key sticks, try tapping it gently or wiggling the steering wheel.

With the key in position I, press down on the catch inside the hole using a screwdriver or awl.

Keep the catch pressed down, pull the key towards you, and extract the barrel along with the key.
Before installing the new barrel, do not forget to swap the immobiliser chip from the old key to the new one, otherwise the engine will not start.