Thank for your reply MyHigh
Here is a picture of the part that is broken -
View attachment 92720
This how the part sits between the cylinder and the ignition switch
The side of the part that is broken turns the ignition switch.
View attachment 92721
I can not find this part in any store or and web site, If I cannot find the part soon, I am considering buying a remote control start system
Thank you for your help
I had this problem yesterday while I was at the motocross track. Little rod broke in the same spot as yours. What I did to get it home was I unplugged the connector and jumped the pins with some spare wire, until I could get it to start. The exact combination is probably different for different models, but mine (1998 tacoma 2.4l manual) required all 4 on the one side connected to each other and the two on the other side connected, then I used the clutch to operate the starter. After it was running I unplugged the pin for the starter.
I have learned since I've been working on it that, if I unscrewed the switch from the back of the key assembly (two phillips head screws), you can turn the switch with a flat blade screwdriver. So for a temporary fix, I'd unscrew the switch. Also makes it possible to get the rest of the broken rod out.
I decided to repair the rod, mainly because I don't want to wait for the parts.
I would suggest that you try to repair it only if you are really handy, and have the proper tools available.
First thing to do is to turn the steering wheel to a position where the lock mechanism doesn't engage, and be very careful not to turn it until you are done. If it locks, you will probably need to remove the whole assembly from the steering column.
Next pull the key cylinder out, and pull out the top portion of the broken rod.
Next get the switch off the back of the lock assembly. The broken pin will probably fall out with the switch removed, if not fish it out.
Now hopefully it will be clear how the broken parts used to fit together, by looking at the fractured surfaces and matching them up.
What I did to join them back together was I drilled a hole down the center of either side and pressed a hex stock into the holes. I used a 1/8" drill bit and a 3mm hex key. I cut of a straight piece off the hex key about 1.5" long, and drilled down the center of the broken pieces a little over 3/4" deep. I pressed the hex key into one side using a bench vise, then I carefully aligned the other side, and pressed it on. There are flats on either end of the rod which should be parallel, that helped make the alignment go a bit easier.
Re-assembly, is easier if you leave the switch loose, while you get everything else working again, you'll probably need to take it off a time or two. Get the rod down the hole, and lined up with the switch and the key cylinder. It will take some fiddling.
If you must remove the whole assembly: I welded a nut to the end of those security bolts. Someone else cut a slot into them and turned them with a screwdriver. I am a professional welder and had the tig welder sitting right there, but even being a pro it was pretty difficult. So I would suggest trying the slot method first.
Good luck.
