I have a 1991 240 with an airbag on the steering wheel...problem is a large crack that gets in the way of me being able to toot my horn on time when I need it. Now, I notice that it doesn't always beep or I have to push it hard to respond. Why is it itermitent? and what do I have to do to have my horn work correctly. I remember that there are contacts underneath but not sure if certain things can be replaced without disruption and cost of the airbag....HELP!, thanks Lynn

Lynn:

Here is the procedure:
1: Disconnect the battery, let car sit for 30 minutes (This is playing it safe).
2: Do not turn the key to the run state, if possible, leave the key out.
3: Remove the top and bottom shell of the steering column. NOTE: All fasteners are probably torx.
4: Remove the torx screws that come in from the back of the steering wheel that hold the air bag in place (I think there are 4 screws).
5: The claymore , er, um, airbag should now be loose, pull it forward and unplug the connector from the back of it, harness has orange covering.
6: Now you should have access to the horn switch plates. Remove the two screws per plate carefully and catch the springs.
7: Now clean the contact pins that are still attached to the steering wheel with 220 grit or finer sand paper.
8: Clean the contact spots on the back of the horn button plates with 220 or finer grit sand paper.
9: Assembly is the reverse order of the above. NOTE: DO NOT reattach the battery or turn the key to the run position UNTIL the air bag is plugged back in and bolted down. REMEMBER, the air bag is a 16 year old BOMB! Just to be safe, after everything is reassembled and the battery is finally reconnected, I normally have a seat on the passenger front seat and turn the ignition key to start the car from there. If all goes well, a few seconds after the car starts, the SRS light should go out. If not, it can be reset... if that happens, let me know, I'll dig up the reset instructions.

Be safe on this one!

jorrell

--
92 245 250K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!

just recently, i had to remove the airbag to reset the contact reel. i was very nervous about it, but it was actually quite simple. i was able to remove the plastic shell around the steering column with a nut driver and torx bits (t25 i think), but ended up buying a torx t30 screwdriver to get the screws on the back of the steering wheel. the nut driver was too big to fit into the holes. during the process, i kept a good distance from the airbag and also started it from the passenger side! i made sure to ground myself before picking up the airbag for reinstallation, just so some static energy wouldn't set off the bag. it is really quite easy.