As a locksmith technician, during many years in the field, you tend to run into the same issues with similar jobs over and over again. One of those repeating problematic situations that I recall is working with Ford 10 cut ignition models. The recurring issue with these type of ignitions is that the ears become loose over time. That type of situation will create difficulty in the proper operations of the key with the ignition. Usually, the solution for this common problem, is replacing the ignition lock, with an addition of instructing the customer not to put too much force on the ears while operating the key, otherwise, the problem will happen again.
After dealing with this type of issue repeatedly servicing Ford ignitions, I came up with a good solution that will prevent the ears on the ignition to come loose again no matter what. First thing first is obviously remove the ignition from the steering column followed by removing the cylinder plug from it as well. Now it is required to insert a proper Ford key blank in order to align the ears with the key-way. Next, locate the groove that held the ears to the cylinder plug.Then, drilling a small hole on the side where the metal on the plug seem to be a little thicker followed by dropping a little epoxy into the hole and insert a roll pin into it. Once the epoxy dries, a little filing on the pin will be required to flush it straight with the plug. This will permanently cause the ears to be attached to the plug.
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