Replacing the ignition lock
Tools needed:
Philips Screw Driver (aka Cross Tip)
22 mm socket with ratchet and extension
Hammer
Chisel
small Flat Tip screw driver
Step 1:  Like everything else in when you do something, disconnect the
battery.
Step 2:  Take off the Kick Panel under the steering wheel
Step 3:  Take the small flat tip and
carefully pry the BMW emblem out of
it's socket. Put it in a safe place (like
where your 19 year old son who
happens to have a 635 CSI also can
not find it.
The 22 mm nut is exposed.  
Remember the position of the steering
wheel before you take it off!
Step 4:  Take the ratchet with the the
22 mm socket and take off the nut.  
After the nut is off, you can pull out the
steering wheel.
Step 5:  Take the cross tip and
unscrew the left screw of the lower
cover.
Step 6:  Followed by the right screw.
Step 7:  Last but not least, take off the
bottom center crew.  Put the cover with
the three screws aside.
Step 8:  Pry off the small cover of the
ignition lock with the flat tip.  That can
be done pretty much anytime, I just did
that at that point.
Step 9: Disconnect the horn
Step 10:  Unscrew the 2 cross tip
screws that hold the Cruise Control
and the Windshield Wiper switches.  
Both of them will then come off.  No
need to disconnect them.  Just let them
hang there.
The cover comes right off.
Step 11: Same for the Turn Signal
side.  There are also 2 screws.
You can leave the relay and all the
other cables connected.
Step 12:  Locate the first shear off
screw and get the chisel going.  It
works best to get a point and direct the
force counter clockwise.
Once that is accomplished and the
screw is loose you can unscrew it by
hand.
Take out the part that holds the lock
cylinder in place.
At this point I lost my photographer,
youngst son Mike since it was a
beautiful day and he wanted to go
skating.  I thought I would be able to
pull the lock cylinder out without
removing the 4 shear off screws but I
was wrong.  If anyone has some
pictures I would appreciate it, thanks!
Step 13:  Chisel out the other 4 shear
off screws.  This loosens up the plate
and you are able to pull out the
cylinder.
Step 14:  Unscrew the small screw (3)
and pull of the cylinder.

Step 15:  Replace with the new one
Here are the 4 shear off screws shown
with the replaced screw that I bought at
the local hardware store.
To put it all together just reverse the
steps.  Good Luck!
BMW 635 CSI Useful Links
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