[nanookvd]

Curious if anyone has taken one of these apart and/or can provide guidance on how to proper re-assemble. The tab on the gear assembly that goes into the ignition barrel sheared off and stranded me with a car in the "On" position and a dead battery a few hours later.

After a tow home, I was able to remove the ignition housing and replace the broken gear. In the process, this switch fell and the internal spring slipped from its position. I was able to take apart and re-install the spring mechanism properly (springs back from "Start") but the small metal plates/contacts don't appear to be in the proper position.

I have continuity between Position (Pos) 30 & S+ at key insertion.

Turning to the "ON" position creates continuity between Pos 30, S+, and X

Turning to "Start" position creates continuity between Pos 30, S+, X, 15, & 54. No continuity to Pos 50 which is the starter.

 

[nanookvd]

UPDATE - After a few disassembly & reassembly attempts, finally got all the components in the correct positions and continuity to Pos 50 when the switch was turned to the "Start" position. Maybe some of my Grandpa's passion in clock/watch repair rubbed off on me

Definitely a PITA & hope to never have to remove the ignition housing again. Repaired & re-installed back to original factory condition.

Great video posted here of exact issue I had with mine. His fix was not applicable to my year Saab as the gear on my 93' has a center hole and pin that is used for the key-in-ignition chime. I ordered a new ignition set although I only needed the one part and the individual parts aren't sold separately.

If your ignition assembly unexpectedly allows you to remove the key in several gears, be warned you may be on borrowed time. Mine finally broke and left me with a free spinning key.

 

[c900]

New ignition switches are NLA and I don't know of any substitute. Kits for the lockout to suit manual and auto configs are I think still available.