Ok, this has been a problem for a while on our 2000 expedition. When we first got the truck it had starting issues. We ended up replacing the ignition switch 2 years ago and when we tried putting it back into the plastic receiver slot under the column it bolted up fine, however the lock cylinder would not start the truck. The key switch will not actuate the pin on the ignition switch far enough to start the engine. And so we have left the ignition switch dangling under the column for 2 years manually starting it that way. I've watched multiple videos on how to install the pin and I'm positive I'm doing it right since there is only one hole for it to go in. I can turn the key all the way back and forth with the ignition switch out and watch the plastic actuator travel all the way up and down in the steering column like it's supposed to. And I even used a small screwdriver inside the slot to simulate the resistance of moving the ignition switch and everything was tight. I could move the lock cylinder manually by moving the plastic actuator underneath the column. I noticed on the ignition switch itself you have to pull the metal pin all the way up against the end of the plastic slide to get it to start, you can't go any less than that or it will not work. This whole problem sucks since the plastic ignition switch does not have adjustment slots like on the older ford ignition switches and I'm at my wits end trying to figure this out. Any help would be greatly appreciated!