Special Tools

J 41340 Lock Cylinder Holding Fixture and Staking Tool

The lock system used for this vehicle is a one key system with a key profile that has a two-sided cut and milled grooves that are unique to this lock system. The teeth of the key locate the tumblers and sidebar, flush to the outside of the lock cylinder from both sides of the cut.

The Exacta key cutting tool kit consists of a 10-position spacing plate, only positions two through ten are used, and a key insert. To install the adapter kit to the key cutting tool, follow the steps in the instruction manual provided with the key cutting tool.

The customer information card or the retailer records will show the key code as a four-digit numeric code. To determine the actual cut sequence of the key for this code, look up the code in the appropriate Key Code book. The cut sequence will be shown to the right of the code listing. The ignition cut sequence should be used to cut new keys, as it has all of the cuts necessary for the key to work properly in all the locks on the vehicle.

1. Insert the key in the approved key cutting tool with the tip of the key against the stop.
2. With the cutting die in the down position, move the carriage toward the die until it bottoms out. Record the depth 1, 2, 3, or 4.
3. Repeat for each position.

Lubricate the lock cylinders with a light oil or graphite lubricant. Never use a silicon spray lubricant.

Each of the 4 depths on the key has corresponding tumblers, sometimes referred to as plates or wafers. The numbers are stamped on the tumblers for identification. Door and liftgate tumblers and ignition tumblers represent 3 different series. There are also three different compression springs. It is essential that the correct components be used in the tumbling of locks. The compression springs are inserted into the springs wells, and then the correct tumblers are inserted into the tumbler wards for the door and liftgate. The ignition is tumbled differently. Insert the correct tumbler into the tumbler wards then insert the tumbler springs on top of the tumblers.

Important: Ignition lock cylinder reads key cut position 2 through 10.

1. Insert the appropriate tumbler (3) according to the key code into the corresponding tumbler ward.



2. The tumblers will not immediately seat into position because the sidebar has been pre-assembled. The tumblers will have to be pushed past the sidebar with a small flat screwdriver or pocket knife.



3. The tumbler springs (2) should then be inserted into the spring wells in the cylinder (4) where they will sit on top of the tumblers.
4. The seal plate (1) will be installed and crimped.
5. Insert the seal plate locator legs into the receptacle slots in the cylinder--seal plate will seat into position only when the two locator legs have been properly inserted into the receptacles on the cylinder.
6. While holding the seal plate in position with the thumb, insert the key into the cylinder and watch for the side bar to drop flush. If the side bar does not drop flush, the lock is tumbled wrong and you need to start over.
7. Ensure that the side bar does not drop on an angle. The side bar must be completely flush to the cylinder diameter.



8. Stake (1) the two metal areas of the cylinder (2) directly over the seal plate legs with a hammer and punch or chisel.
9. Repeat this stake on the areas of the cylinder directly opposite of the first to stakes.

1. Handing is determined by color of pawl. Orange is left hand and green is right hand.




Important: The door lock cylinder reads key cut position 4 through 9.

2. Insert the appropriate tumbler (5) according to the key code into the corresponding tumbler ward.
3. The tumblers will not immediately seat into position because the sidebar has been pre-assembled. The tumblers will have to be pushed past the sidebar with a small flat screwdriver or pocket knife.
4. The tumbler springs (4) should then be inserted into the spring wells in the cylinder (3) where they will sit on top of the tumblers.

1. With key inserted into cylinder, insert cylinder into housing (2). This will hold the pawl (1) into position once the cylinder is inserted into the housing.
2. Shutter (8) and compression spring (6) are pre assembled to the cylinder in the service package.
3. Install the cap (9) by aligning the notch in the cap with the large drain slot in the housing and pressing the cap until it bottoms out and snaps onto the housing (2).

1. Select the correct lock tumblers for the desired code by the number stamped on the tumbler.



2. Install lock tumblers (2), by applying downward pressure until locked into position.

Important: When key is inserted into correct coded lock cylinder, all tumblers except the retainer is flush with the lock cylinder.

3. Check coding of lock cylinder (4). Insert key.