Re-shelling Ford Integrated Keys

Lexus introduced the first remote head key in the mid-1990s. Early Lexus remote head shells were held together using a Phillips head screw. Since that time, additional manufacturers have added remote head/integrated keys and the shell manufacturing process has evolved to produce sealed plastic head keys, designed to prevent disassembly.

Today’s passenger vehicles are being financed and owned for a longer period. The average car loan has grown to 67 months, over five and one half years. In the first quarter of 2014, Experian Automotive reported that almost 25 percent of all new-car loans were 73 to 84 months long. And vehicles are being driven for more than 12 years, resulting in significant wear and tear on the key.

Gone are the days of a $2 duplicate automotive key. Duplicate plastic head transponder-equipped keys can be costly. This makes customers less likely to replace their remote head/integrated key just because the key does not smoothly rotate when starting the vehicle. This usually leads to the shell breaking off the blade. Once the vehicle owner’s last key breaks, he or she is finally forced to contact a locksmith or go to the dealership.

Since the cost of replacement remote head/integrated keys have skyrocketed, many vehicle owners are opting to re-shell their keys instead of replacing them, saving the cost of programming that car dealerships usually require. The cost of a replacement shell varies by manufacturer. Needless to say, it is much less expensive than the cost a new integrated key plus the cost of programming.

To this end, shells have become available for many vehicle manufacturers' remote head/integrated keys. These include Chrysler, Dodge, Jeep, General Motors, Ford, Lincoln, Mercury and many "world" vehicles including Acura, Honda, Lexus, Mitsubishi and Toyota.

Vehicle manufacturers offer different shell configurations with differing numbers and sizes of buttons and differently sized shells. The Ford Integrated key shell varies by the blade; sidewinder or 8-Cut. Lexus remote head shells also vary by blade.

For this article, we will re-shell a Ford Integrated key. Replacement Ford integrated key blank shells come in four components: front cover, rubber pushbutton pad, interior housing with attached blade and rear cover without logo. I prefer to re-use the customer’s pushbutton pad and logo rear cover if they are in good condition.

Use a battery operation hand grinder 80 grit sanding band to remove the welded area from the existing shell. Once the welded area has been ground away, the two outer halves of the shell will separate. Disassemble the shell, separating the five pieces.

Discard the interior housing with blade and the front cover.

Carefully clean the rubber pushbutton pad, the circuit board and the logo rear cover. Use a mild spray cleaner for the rubber pushbutton pad and the rear cover. Use a circuit board cleaner for the circuit board.

If the rubber pushbutton pad is worn, remove the contact, which is a clear insert on the underside of the customer's rubber pushbutton pad. There are two tabs on the rubber pushbutton pad. Locate the contact so the tabs slide through the openings to maintain position.

Place the rubber pushbutton pad into the front cover and the circuit board on top of the pad in their proper positions. Insert the battery through the opening in the interior housing with attached blade.

Use a cyanoacrylate adhesive, commonly known as Super Glue or Crazy Glue, to attach the front cover to the interior housing. Use the adhesive’s a brush-on applicator to go around the outer lip to ensure the glue is exactly where you want it.

Carefully place the front cover onto the interior housing.

Use two one-inch clamps to secure the two pieces together.

Dry time is about 20 minutes. Once dry, install a new battery and snap the original rear cover in place.

For more information, contact your local locksmith distributor or visit the following manufacturer websites: