Ignition key sticks

[abdelhamid.amr]

I have a standard 1972 bug that I recently fully restored
I change the ignition switch cylinder and the electrical switch in the process
Now intermittently, the ignition switch goes in and then won't turn and i have to try for a very long time (last time 80 min.) until the switch finally twists and I can start the car
I was almost stranded 100km away from home last week.
What do u suggest I should do give that I have new cylinder and new switch

[Brian]

How's the condition of the key?
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'69 Bug
'68 Baja Truck
'71 Bug
'68 Camper

Only losers litter

[abdelhamid.amr]

The key is brand new as well as the cylinder and switch

[Cusser]

[ashman40]

[abdelhamid.amr]

I know how to wiggle the steering wheel to free-up the lock. This is not the case. It is jammed no matter what I do. It is an intermittent issue.

[OTTO 1303]

Sounds like an issue with mating surfaces of the key drum components.

The mechanical portion of “NEW” switches are not as smooth as the OG.

Recommend removing the tumbler and polishing the mating surfaces to remove any casting slag and smooth the surfaces. This would include the mating surface of the steering lock, if so equipped.

You should be able to see what rubs what and go from there.

Good luck.
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74 Super Sun Bug - OTTO
74 Super - DANZIG
74 Super - HERZOG

[ashman40]

It could also be an internal failure in the electrical portion of the switch. There are springs and detent balls in there. The plastic can crack and then jam the rotation.

You may want to take the time to test the electrical switch outside the assembly and make sure the movement is smooth. Check the movement of the key cylinder in the assembly and the action of the locking bolt. A spray of silicone lubricant could help to smooth the action out.

Also check that the end of the "pin" that extends from the cylinder into the electrical portion has the proper shape. Different model years came with different shapes for this pin.
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AshMan40
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'67 Beetle #1 {project car that never made it to the road }
'75 Beetle 1200LS (RHD Japan model) {junked due to frame rot}
'67 Beetle #2 {2019 project car - Wish me luck!}

[mj2k]

As everyone above has suggested, best to remove the lock and try it on the bench. Chances are, if it's new, depending on the quality, there could be burrs on the new lock tumblers, or the key isn't perfectly matched if it's one of the newer 'double sided' keys.

If it is one of the newer locks, try it with the key inserted in one direction, then take the key out, turn it through 180 degrees and try again. If it's fine in one direction but not the other, put a mark on the key so you know which is the best way to insert it into the lock.

If you notice any issues with smoothness, take the electrical portion off and retry. From there you should know if there are any issues with the new lock, and from there you can decide whether to return/replace it (best idea if there are issues with the electrical portion), take it to bits and deburr the lock plungers, or if it's only sticking a bit, live with it until the key / lock have 'worn in'.

If it's 100% smooth on the bench, chances are either the section on the steering column it engages with are burred / rusted / damaged (most likely if you had to replace the lock because the old one had been forced), or it's the wrong lock for the car.

[dennismcd707]

I have a similar issue, and thought that I'd chime in in case others did too. My ignition switch seems to work fine, but the key reminder portion of it is stuck. In order to make the key reminder 'stop' buzzing, I have to wiggle and turn the key in the ignition switch, over and over, until finally the cylinder pops outs and the buzzing stops. This gets old real fast.
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1971 Super Beetle, 1776, dual Weber's, roller crank, big valve modified racing heads, close ratio trans, lowered suspension, 4 wheel disc brakes, car has over 368,000 actual miles. (RIP 1970 Beetle/Baja, 1986 GTI, 1999 Jetta, 2002 Jetta)