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Old 04-01-2021, 11:26 PM   #1
zammmmm
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Default 04 ion key stuck need help tried all fixes

Ok very common question i know...

key stuck in acc

installed a new lock cylinder with key. still turns on but only goes into acc and stays stuck tried to use the trap door plunger didnt work, took the center console out and looked the shifter to see if it triggers the plunger it does. key still stuck. replaced the btsi solenoid key still stuck. put in a new ignition switch key still stuck , now i have the passlock issue. now the car wont start at all from what i have read to reset the passlock i need to let the car set 15 mins until light on dash stops blinking then turn car off for a few mins but i cannot turn the car off only too acc,. any more ideas TY
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Old 04-02-2021, 05:46 PM   #2
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2003 L-Series 3.0L Sedan
Default Re: 04 ion key stuck need help tried all fixes

If I'm not mistaken, the ignition switch has an embedded resistor that's part of GMs Passlock security. The ignition switch replacement created an added issue because it's not recognized and triggered security (flashing security indicator). There's 30 min relearn procedure requiring cycling ign on for 10 minutes then off and repeating two more times. On the fourth try, the resistor is learned and accepted as a new security signal with security turning off to allow starting.

The ignition switch isn't the problem. You should be able to put the original ignition switch back without performing the 30 min Passlock relearn procedure.

You were correct finding the lock cylinder hanging up. I'm not 100% familiar with how the lock cylinder works as its both a mechanical and electrical set-up. Mechanically, a pin is used prevent turning the lock cylinder all the way to OFF if the shift lever isn't in Park/P position. there may be a cable between shift assembly and ignition lock assembly. Whether this is a mechanical or electrical set-up, others may know. The Brake Transmission Shift Interlock (BTSI) solenoid works with the brake pedal switch. Due to a failure decades ago from Audi 5000 owners failing to know the difference between gas and brake pedal, mysterious drive aways were blamed on the vehicle. The phrase 'pedal misapplication' was coined shortly afterwards. All vehicle manufacturers wanted nothing to do with lawsuits of lazy drivers so the 'apply brake pedal before shifting from park to drive or reverse is incorporated into USA cars. I don't know if it applies to pickup trucks and suvs. Ignition On forces one to apply brake pedal to power up the btsi solenoid to release the shift lever from Park position. In ACCessory position, brake pedal depressed isn't needed to move the shift lever.

To allow the ignition switch to return to OFF position, the shift lever must be in Park position. I tried this on my '03 L300 and presume this applies to all Saturns with automatics. If there are subtle differences, I'm open to correction.
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Old 05-06-2021, 09:58 PM   #3
alternator guy
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Default Re: 04 ion key stuck need help tried all fixes

Cross-posted from other thread:
http://www.saturnfans.com/forums/sho...d.php?t=268551

For anyone who landed in this thread looking for passlock / passkey / VATS help, here is my data on the resistor values. My shop sells a kit with 10 of each intended for repair shops, but you can just order one each of the resistors straight from Mouser.com and try them one at a time.

#---RESISTOR#----CODE-OHMS
1. MF1/4DC4020F NONE 402
2. MF1/4DC5230F CN 523
3. MF1/4DC6810F FW 681
4. MF1/4DC8870F GP 887
5. MF1/4DC1131F KA 1130
6. MF1/4DC1471F N5 1470
7. MF1/4DC1871F UN 1870
8. MF1/4DC2371F XB 2370
9. MF1/4DC3011F GA 3010
10. MF1/4DC3741F NP 3740
11. MF1/4DC4751F FY 4750
12. MF1/4DC6041F C5 6040
13. MF1/4DC7501F XY 7500
14. MF1/4DC9531F KB 9530

Here is a technical overview of the VATS system on my Dropbox:
https://www.dropbox.com/s/s3uln7lq08...rview.pdf?dl=1

Here is my VATS kit BOM on my Dropbox:
https://www.dropbox.com/s/iykm693ybx...20BOM.txt?dl=1
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Old 05-10-2021, 03:17 PM   #4
MorganIOn
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Default Re: 04 ion key stuck need help tried all fixes

GM has issued a recall on the ignition switch for certain model year Saturns. I've received two notices (one when I had my emissions done and one in the mail). You can go to any GM dealership and have it replaced for free.
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Old 05-21-2021, 12:19 AM   #5
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Default Re: 04 ion key stuck need help tried all fixes

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