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Assembling & Coding Procedure

WARNING: This page is about a different car, the 2004 GMC Safari and 2004 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Determine the tumbler numbers/arrangement:
    1. Place the tip of the key directly over the tip of the illustrated key.
    2. Inspect that the diagram outlines the key.
    3. Starting with position 1 (open end of cylinder), find and record the lowest level (tumbler number) that is visible.
    4. Repeat the previous step for positions 2-10.
    Fig 1: View Of Key Tumbler Numbers
    GM65496Courtesy of GENERAL MOTORS CORP.
  2. Starting with position 1, insert the tumblers (4) into their corresponding slots in the coded order.
  3. Using your fingers, pull out the side bar (3) until the tumblers fall completely into place.
    Fig 2: Installing Tumblers
    GM65498Courtesy of GENERAL MOTORS CORP.
  4. Insert one tumbler spring (2) above each tumbler (4).
  5. Lubricate the tumblers using Superlube® GM P/N 12346241 or equivalent.
  6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder.
    Fig 3: Inserting Lock Retainer
    GM65499Courtesy of GENERAL MOTORS CORP.
  7. Press down the retainer (1) until fully seated in the depression.
  8. Inspect for proper tumbler installation:
    1. Hold the spring retainer (2) in position.
    2. Insert the key (1) into the cylinder.
    3. The side bar (3) should drop down flush with the cylinder diameter if properly installed.
    4. Disassemble and assemble properly as needed.
    Fig 4: Inspecting Tumbler
    GM65501Courtesy of GENERAL MOTORS CORP.
  9. Remove the key.
  10. Secure the cylinder in the J 41340  .
    1. Inspect that the spring retainer is facing up and positioned directly under the punch slots.
    2. Push the cylinder into the J 41340  until butted with the cylinder bezel.
    3. Tighten the holding screw.
    Fig 5: Securing Lock Cylinder Into J 41340
    GM65502Courtesy of GENERAL MOTORS CORP.
  11. Stake the bezel end of the retainer in place:
    1. Hold the flat side of the punch, part of J 41340  , squarely against the face of the cylinder bezel.
    2. Stake the lock cylinder metal over the retainer corners.
    Fig 6: Staking Spring Retainer
    GM65503Courtesy of GENERAL MOTORS CORP.
  12. Stake the other end of the retainer:
    1. Remove the punch, part of J 41340  .
    2. Rotate the punch, part of J 41340  , 180 degrees.
    3. Hold the punch, part of J 41340  , squarely against the end of the punch slot on.J 41340  .
    4. Stake the metal over the other end of the retainer.
      Fig 7: Staking Opposite Spring Retainer
      GM65504Courtesy of GENERAL MOTORS CORP.
  13. Loosen the holding screw.
  14. Remove the cylinder from the J 41340  . See Special Tools and Equipment .
  15. Inspect that the retainer is properly staked. Restake as needed.
  16. Lubricate the cylinder retainer slot.
  17. Insert the following parts into the cylinder retainer slot:
    • The retainer spring (2)
    • The retainer (3)
    IMPORTANT: Use a paste type grease, not a spray, for the following step.
  18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed:
    • The detent pins (1)
    • The cylinder retainer (3)
    Fig 8: Lubricating Lock Cylinder Retainer & Retainer Spring
    GM65505Courtesy of GENERAL MOTORS CORP.
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