Coding A Lock Cylinder To Existing Key (Hi-Security)

NOTE:

There will be additional parts leftover once service has been completed.

NOTE:

The following procedure will be show for a door lock cylinder. All other cylinder coding is similar.

NOTE:

When marking tumblers for door lock cylinders, there will be seven markings, eight markings for ignition lock cylinders, and four markings for the fuel cap lock cylinder.

NOTE:

There will be multiples of each tumbler (AL, BL, CL, DL, AR, BR, CR, DR) and they will be Individually bagged

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1 - Cap

6 - Right Side Tumblers (Marked AR, BR, CR, DR)

2 - Gasket

7 - Existing Key

3 - Lock Cylinder Ring

8 - Tumbler Springs

4 - Lock Cylinder Housing

9 - Lithium Grease

5 - Left Side Tumblers (Marked AL, BL, CL, DL)

TYPICAL CONTENTS OF LOCK CYLINDER KIT

1.	Cap
2.	Gasket
3.	Lock Cylinder Plug
4.	Lock Cylinder Housing
5.	Left Side Tumblers (Marked AL, BL, CL, DL)
6.	Right Side Tumblers (Marked AR, BR, CR, DR)
7.	Existing Key
8.	Tumbler Springs
9.	Lithium Grease

Insert an existing key into the lock plug and identify the location of the tumblers.
NOTE:
When marking tumblers for door lock cylinders, there will be seven markings, eight markings for ignition lock cylinders, and four markings for the fuel cap lock cylinder.

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1 - Tumblers
Mark tumbler location on key.

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Remove the key, rotate the cylinder plug and mark the additional notches.
NOTE:
The first side will use the left side tumblers marked AL, BL, CL, DL, the send side will use tumblers marked AR, BR, CR, DR.
Determine tumbler depth for each of the locations marked and write them down.
Lay out tumblers left to right for first side (Positions 1, 3, 5, 7) and second side (Positions 2, 4, 6) as shown in the illustration.

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Apply a small amount of lithium grease on springs and insert springs into the first side.

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1 - Tumbler Spring
With all of the springs are inserted, apply lithium grease on the top side of lock cylinder plug to help prevent them from falling out during assembly.
NOTE:
The first side will use the left side tumblers marked AL, BL, CL, DL

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1 - Lock Cylinder Plug
Starting with position one on the first side, insert the proper tumbler into the lock cylinder plug.

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1 - Tumbler

2 - Lock Cylinder Plug
Insert the key and verify that the tumbler will be flush with cylinder plug.

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1 - Tumbler

2 - Lock Cylinder Plug
Continue down the first side, completing the installation of all tumblers and verification of proper installation.
NOTE:
The second side will use the right side tumblers marked AR, BR, CR, DR.

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1 - Lock Cylinder Plug
With the first side completed, hold the installed tumblers loosely to prevent them from falling out, rotate the lock cylinder plug the to second side. Repeat the previous steps for the second side until all positions are filled.

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1 - Lock Cylinder Plug

Insert the key (1) into the lock cylinder plug (2) and position them inside the lock cylinder housing (3).

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1 - Key

2 - Lock Cylinder Plug

3 - Lock Cylinder Housing

Verify proper operation of the lock cylinder by turning the key (1) and removing it.

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Key
Remove the marks from the key and continue with cylinder installation.