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Thread: 2001 P38 4.6 ignition barrel stuck in position 3.

  1. 17th December 2025, 03:43 PM #1
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    PeterH
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    2001 P38 4.6 ignition barrel stuck in position 3.

    You won't believe this, I was changing my leaky heater core o rings, got them in, turned the engine on to check and coolant started pouring out.
    So I tried to turn the engine off and found the ignition barrel had chosen that exact moment to fail.
    So there I am with a running engine I can't turn off and coolant escaping into the cabin.
    I disconnected the battery, but of course it kept running off the alternator.
    How the hell do I stop the engine!
    After thinking about it, I undid the air filter housing and blocked the air intake with my hand, which did stop the engine. PHEW!
    P38's really do try us out sometimes.

    My ignition barrel has been a bit clunky lately, I have to put the key in carefully, but it still worked ok.
    So now I have the key position stuck in position 3 (running position) and the key will not turn.
    I can remove the key ok, just not turn the barrel.
    The steering isn't locked.
    I've tried some graphite powder to no avail and also putting the key in and out repeatedly, wiggling the key, nothing is working.
    I'm suspecting the barrel is just worn with age.
    Am I up for a new barrel or is there a way to get it working again?
    Any help appreciated, thank you, Pete.
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  2. 17th December 2025, 08:45 PM #2
    prelude
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    What worked for me is to tap on the key with a hammer. Carefully, goes without saying. what that seemed to do is shake the ends back in place around the key. Thing is that the P38 flip-open style keys are not very sturdy for some light tapping. If that does not work, you might want to take the plastic covers off and try to tape on the barrel itself. Chances are though that the spring inside has simply failed or is no longer strong enough to do it's job.

    Good luck with that job mate! (and drying out your carpets, though summer is on it's way down undah right?

    Cheers,
    -P
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  3. 18th December 2025, 10:22 AM #3
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    PeterH
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    Hi Prelude, thank you for the reply, yes summer is here, 36 in Melbourne today, the carpets should dry out ok!
    I went back out last night with determination and a can of contact cleaner, gave it a good spray with the key partially inserted to allow the cleaner to get in there.
    After a few good blasts and much key jiggling, the key turned to the off position and stuck there.
    At least I could reconnect the battery.
    So I kept at it, a few more sprays and jiggling in all directions and what do you know it started working again.
    I really thought it was game over for the ignition, but all working well again today.
    It's been a bit sticky for a while now, so I'm guessing it was gummed up and stuck, but contact cleaner did the job.

    I've bypassed the heater for now, so I have a usable car again.
    I can't quite get the new o rings seated properly, it leaks as soon as I turn the engine on.
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  4. 19th December 2025, 09:26 PM #4
    prelude
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    if it works, it ain't stupid.

    The O-rings, maybe one size off?

    -P
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