How I solved my 2001 S60's $400 key problem for $17

[paul1149]

Along the way one of my keys stopped working. It would operate everything at ignition position I and II, but it brought a "Start Prevented" error when trying to start the engine. That left me with one operating key, and with thoughts of the cost of being towed to the dealer and having 2 new keys cut if it went bad. The dealer had quoted me "$400, and don't hold me to it" when I priced a replacement key.

I came across various ways to purportedly make the defective key work again, involving rapidly repeated cranking attempts, but the dealer cautioned me against confusing the onboard electronics, which would be even more expensive to correct. I heeded the warning. It wasn't working anyway.

In a forum I came across the idea, which strangely was ignored, of removing the transponder from the working key, taping it to the ring antenna, and then using cheap replacement keys without the transponder. Brilliant. But when I dissected the non-working key, I concluded that removing the transponder in one piece was a very difficult job.

So instead I used the whole key. I don't have pictures, but this helpful video by Peppermint, who I believe posts here, shows the way the ring antenna is situated and how to get to it:



You only need to take off the upper steering column shroud, which snaps right off without tools. I found the best position for the key was directly on top of the antenna, key blade facing forward.

NOTE: The first thing I did now was to drill out the transponder in the non-working key. I did not want the car's module to receive two different messages at the same time. The non-working key was now totally inert.

I then had to experiment to see which side of the key should face outward. Once I found the correct side I taped it in place with gorilla tape, and snapped the shroud back on. I tested the idea with my non-functional key, with my key fob out of proximity, and it worked perfectly.

Then I went to aliexpress and ordered two new keys without transponders. Cost, about $3.25 per. I then added on their key cutting service, at $4 each. Total, about $17. My keys came five weeks later, and they work perfectly.

By doing this, I am neutralizing the anti-theft aspect of the Volvo's transponder keys. But considering the age of my vehicle, and the security of having extra keys, that's an easy trade-off. Aside from the "installed" key I now have three other functioning keys, including the original non-working one and the two new ones, a $1200 value, for $17.

[br0dy519]

Curious about this $4 key cutting service. Can you go into further detail? All my research has lead me to believe I require a locksmith that can do laser cutting which in my area is over $100.

[paul1149]

Very pleased with it. You simply take a clear picture of your existing key - they give instructions - and they take it from there. Painless.

[matthew1]

Brilliant, thanks for the post, Paul.

[paul1149]

Thank you, Matthew. Be well.

[abscate]

Despite Matt’s attempt to elevate the P2 forum above the cool kids in the P80 forum, the key near transponder trick is old school to the P80 world.

Glad it worked out! You can get a pending code for “ key in too long” on some engine management systems but that generally won’t trigger a CEL

[jonesg]

I think I'll try it too, my car only came with one key.

https://www.aliexpress.com/item/2251832 ... 0774%21sea

[paul1149]

That's the same service I used.

[ZionXIX]

I'm preparing to do exactly this. I've ordered some refurbished keys that have blank blades. I was playing with the idea of buying one of these cheap transponder cloners. I've seen them for $100 to $150 which is cheap enough if you have a lot of P2 cars to make it worthwhile. Maybe even cheap enough for the "loaner" program. What confuses me is they all describe id48 chip tokens that have to be purchased for a few dollars or some that give 1 free token per day and so forth. Can old transponders be reprogrammed? Do I have to buy their blank transponders and replace the used ones?

I feel like taping the current transponder to the antenna ring is cheaper and better for future proofing the car.

I can live with a "key in too long" code.

[paul1149]

You can get a pending code for “ key in too long” on some engine management systems but that generally won’t trigger a CEL

I didn't know about that code, but I was concerned about the effect of having the key "in" all the time. But I reasoned that circuit would only register when the key is turned past Position II, and that it really shouldn't matter anyway. But I guess that's not how Volvo thinks. But no code has surfaced on my P2.