Ignition Barrel Replacement in Ford Transit: Diagnosis, & Prices

The Ford Transit is a trusted work van. Many businesses rely on it every day. But sometimes the ignition barrel stops working right. This is the part where you put your key to start the van. When it breaks, you can’t drive. This guide shows you how to spot problems and fix them.

Your van might show warning signs before it stops working. The key might stick. It could be hard to turn. Sometimes the van won’t start. Fixing these problems early saves you time and money. You won’t get stuck with a van that won’t start.

What Is the Ignition Barrel?

The ignition barrel sits in your steering column. You put your key in this metal cylinder. When you turn the key, it starts your van.

Main Parts:

• Lock cylinder – Holds your key in place.
• Metal pins – Match the cuts on your key.
• Ignition switch – Sends power to the starter.
• Steering lock – Stops the wheel turning without a key.
• Chip reader – Checks your key is correct.
• Wires – Connect to the electrical system.
• Spring – Returns the key to position.

Older Transit vans have simple systems. Vans from 2006 onwards have better security. New models have computer chips in the keys. Without the right chip, the van won’t start.

Barrel Sizes

Each Transit model needs a specific barrel size.

Basic Measurements:

• Length – 95 to 110mm
• Width – 20 to 22mm
• Housing – 30 to 35mm
• Key depth – 40 to 45mm
• Material – Zinc and steel
• Pins inside – 5 or 6
• Wires – 4 to 7 connections

Transit Custom vans need different barrels than standard Transit vans. Transit Connect models use smaller parts. Always check your van’s year and model before buying parts.

Signs of Problems

Watch for these warning signs.

Lock Problems:

• Key is hard to turn.
• Key won’t go in all the way.
• Key gets stuck inside.
• Van only starts sometimes.
• Key turns too easily.
• Grinding noises when turning.
• Keys break in the barrel.
• Barrel moves around.

Electrical Issues:

• Warning lights on the dashboard.
• Radio and lights don’t work.
• No sound when you turn the key.
• Lights flicker.
• Engine starts then dies.
• Nothing works at all.
• Security system rejects your key.

Security Problems:

• Someone tried to break in.
• Steering wheel stays locked.
• Key stuck in start position.
• None of your keys work.

Don’t ignore these signs. Small problems get worse fast. Fix them before you get stuck.

What Makes Transit Barrels Different

Transit barrels are built for heavy work.

Security Features:

• Coded chip system stops theft.
• Security codes change each time.
• Needs key shape and chip together.
• Steering column locks physically.
• Records break-in attempts.

Strong Build:

• Made for daily commercial use.
• Rust protection coating.
• Tough internal parts.
• Springs last longer.
• Keeps out dirt and water.

Easy Use:

• Comfortable reach from driver seat.
• Feel each position clearly.
• Works in freezing weather.
• Can use with work gloves.

Work vans start and stop many times daily. Transit barrels handle this wear. They’re tougher than car ignition systems.

How to Replace It

Most people hire a mechanic for this job.

Preparation:

• Check your van’s exact model.
• Get security codes from Ford.
• Gather the right tools.
• Have key programming equipment.
• Disconnect the battery.
• Turn off airbag system.

Removal:

• Take off steering column covers.
• Unplug the wires.
• Drill out security bolts.
• Release the steering lock.
• Pull out old barrel.
• Check for damage.
• Clean wire contacts.

Installation:

• Check the new barrel fits.
• Line it up correctly.
• Put in new security bolts.
• Test before final tightening.
• Tighten until bolt heads snap.
• Plug wires back in.
• Check steering lock works.

Programming:

• Code new keys to computer.
• Make systems work together.
• Delete old key codes.
• Program at least two keys.
• Test all functions.

This job takes two to four hours. You need special tools and programming equipment.

Cost Breakdown

Prices vary based on where you go.

Parts:

• Ford barrel: £120 to £280
• Good aftermarket: £60 to £150
• Cheap aftermarket: £35 to £80
• Blank keys: £25 to £80 each
• Bolts: £10 to £20
• Connectors: £5 to £15

Total Job:

• DIY: £80 to £200
• Local shop: £300 to £550
• Ford dealer: £500 to £850

Save Money:

• Program several keys at once
• Fix problems early
• Choose mid-range quality parts
• Get multiple quotes
• Check your insurance

For work vans, lost time costs money too. Add towing and rental costs if needed.

Making It Last

Simple care extends barrel life.

Key Care:

• Keep keys clean
• Use light keychains
• Turn gently
• Store spares properly
• Replace worn keys
• Get professional key copies

Lubrication:

• Use graphite powder only
• Apply once per year
• Use small amounts
• Blow out dust with air
• Never use oil or WD-40

Good Habits:

• Push key in fully
• Move through positions smoothly
• Don’t wiggle the key
• Fix stiffness immediately
• Let frozen locks warm up

Protection:

• Cover during pressure washing
• Use steering wheel covers
• Fix interior leaks
• Prevent rust in salty areas

Regular Checks:

• Inspect during yearly service
• Test electrical connections
• Watch for warning lights
• Listen for new sounds
• Fix small problems fast

These steps help barrels last 200,000 miles or more.

Ford Parts vs Aftermarket

You have two choices for replacement parts.

Ford Original:

• Fits perfectly
• Works with security systems
• 12 to 24 month warranty
• High quality materials
• Lasts longer
• Dealer support available
• Costs more
• Has latest updates

Good Aftermarket:

• Costs 30% to 50% less
• Decent quality brands work well
• 12 month warranty
• Easy to find
• Fits properly
• Works with most systems
• Quality varies by brand

How to Choose:

• New vans need Ford parts
• Work vans need reliability
• Budget affects choice
• Keep warranty with Ford parts
• Older vans can use aftermarket

Mechanics recommend Ford parts for vans under five years old. Work vans that run daily should use Ford parts. Older vans can use quality aftermarket brands. Never buy the cheapest option.

Conclusion

Ignition barrel problems in Ford Transit vans need quick attention. Watch for warning signs like sticky keys or starting problems. Good maintenance makes barrels last longer. When replacement is needed, choose quality parts that fit your budget. Ford original parts work best for newer work vans. Quality aftermarket parts suit older vehicles. Fix problems early to avoid getting stranded and keep your business running smoothly.