The aluminum device that connects rod from the key switch to the ignition switch located on the column under the dash broke. I have replaced it and re-assembled the column. I cannot get the gears attached to the ignition cylinder lined up. With both parts out of the column in hand I can get it to work properly. When I install it inside the shroud it will not allow the key to turn to the lock position. What am I doing wrong? Any and all comments will be greatly appreciated. I am going to try to attach a couple of pictures. Where I have the screw driver pointed the two pieces should be literally flush, the internal piece is 6/16" +/- lower than it should be.

 

I am going from memory, so this may be wrong. Is this the rack that runs down the column to the switch? If so, I believe the switch can be adjusted back and forth also. Again, has been many many years I dealt with this.

 

You are correct that this is the rack that runs down the column to the switch. What I am trying to install does not include the switch. When I install the mechanism that moves the rod I cannot get the key to the locked position or remove it.

 

Maybe this will help?

https://www.ford-trucks.com/forums/8...-actuator.html

 

when i install the rack and gear, i align them so both first gears match. put them in, then put the rod in the switch.
i then put the key in acc position, and switch in acc position. then i snug the bolts on the switch and check to ensure the switch functions in all positions before tightening everything up.
if you have the rack and gear one tooth off, it will not work properly

 

Finally found the problem, crappy casting from the far east, I had to grind about 3/32" from the end of the casting that fits into the rack and gear to allow the switch to move to the lock position. Thanks to everyone for the help and information!!