Hopped in my '96 250 PSD after work today, inserted the key with the usual smile of anticipation at driving my rig home, only to have the smile wiped from my face by a strange feeling of lost resistance to key turn. Steering wheel unlocked, shifter would slide to drive, wait-to-start light lit and quit as usual, but the key wasn't pushin' whatever it usually does to sent the starter to spinnin'. Am fortunate to own two 3/4 ton PSD's, a '95 2WD and this '96 4X4. Got my bride to fetch me home where I removed the 95's Ignition Switch Lock Cylinder and Multiple Switch, hoping that one or the other in the stranded '96 had said bye-bye. Back at work I switched both out. No go. Somethin' ain't right in the mechanical part of this equation. Spring torque is missing at the key turn. Jumped solenoid with key in as far clockwise position as it would rest. Won't start. Feels as though if someone held the key that little bit more CW it would start, but didn't try on accounta I would never try to go down the road torquin' a key. I'm guessin' it's gonna be beyond my means to fix.

Snow's on it's way down the hillside here in Anchorage, so I'm gonna need this rig functional soon. Anyone have an idea of what's ailin' ol' blue? Will tow to shop if I don't hear anything. Thanks for readin' this.

 

it sounds like the ignition switch actuator cam inside the column broke.
it is a cheap part to buy, but a bear to install. you have to take the top of the column apart to put it in.

 

The 92-96 columns are actually very easy to get apart, assuming you have set of torx tips or screwdrivers.

Disconnect the connectors on the column, then undo the berg joint at the bottom of the column, then undo the four large bolts that hold the column up against the aluminum column support.

The column should be free, so remove it and put it on your table/workbench/garage floor.

There are two torx at the top of the column, and two towards the shaft output at the back, all on the top side that holes the gearshift lever and slides in place. They look like fancy, cast pipe clamps. Remove both those clamps and wiggle the shifter, and it should come off fairly easy. Then you have access to the pin.

To reassemble, do the reverse.

 

I have the torx set, but it looks like I'll need a steering wheel puller too. From service manual on disc that came with the rig (used).

Steering Wheel

Removal

1. Center front wheels (1007) to the straight-ahead position.

2. Disconnect the battery ground cable (14301).

3. Unsnap the steering wheel pad horn switch (13A805) from the steering wheel (3600) by grasping the sides of the steering wheel pad horn switch and pulling toward yourself.

4. Disconnect the horn/speed control wire harness connector from the air bag sliding contact (14A664), and remove steering wheel pad horn switch from steering wheel.

5. Remove steering wheel retaining bolt.

6. Install Steering Wheel Puller T67L-3600-A, and remove steering wheel.

Steering Column

Disassembly

1. Disconnect battery ground cable (14301) and air bag backup power supply (if so equipped). Refer to «Section 14-00».

2. Remove steering wheel (3600).

And the procedure reads pretty much like what you've said, Frederic.
Well, there's no airbag, at least. I'll see if I can track one of these pullers down.

Will let you know whether this "very easy" bear of a task mauls me into submission and a tow, or if I return to watch you and tjc transport argue semantics. For now, many thanks to you both.

3. Remove steering column from vehicle.

4. Remove lower U-joint, spring sensor ring and tolerance ring.

5. Remove turn indicator cancel cam (13318) by pushing up with flat-bladed screwdriver. Note direction of flush surface.

6. Remove bearing retainer (3C610) and steering column upper bearing spring (3520).

7. Remove steering column bearing sleeve (3518) and steering column bearing tolerance ring (3L539).

8. Remove ignition switch (11572).

9. Remove shift lock actuator retaining screws and remove shift lock actuator.

10. Remove transmission column shift selector tube (7212) and transmission shift selector position insert (7A216) (column shift only).

11. Using a drift, tap steering column lock lever pin (3B663) loose. Remove steering column lock lever pin with diagonal pliers. Remove steering column lock pawl (3E691).

12. Remove plastic bearing retainer from lock cylinder housing bore.

13. Remove steering column lock housing bearing (3E700) from lock cylinder housing bore.

14. Remove steering column lock gear (3E717).

15. WARNING: THE STEERING COLUMN POSITION SPRING (3D655) WILL RELEASE WHEN THE PIVOT BOLTS ARE REMOVED.

Remove two pivot bolts. Use caution as steering column position spring will release when bolts are removed. Remove steering column lock cylinder housing (3511).

16. Remove steering shaft from steering column.

17. Remove steering column lock lever actuator (3E715).

18. Remove steering column lower bearing retainer (3D681) and steering column lower mounting bracket.

19. Remove tilt lock lever pivot pin using a drift. Remove steering column locking levers and springs.


Assembly
1. Install steering shaft into steering actuator housing (3F723).

2. Install steering column lower bearing retainer and steering column lower mounting bracket. Tighten screws to 7-11 N-m (62-97 lb-in).


3. Install sensor ring, tolerance ring and spring to steering shaft.


4. Lubricate steering column lock actuators with Ignition Lock Grease F0AZ-19584-A or equivalent meeting Ford specification ESA-M1C232-A prior to installation. Position steering column lock actuators in steering actuator housing.

5. Position steering column lock pawl in steering actuator housing and install steering lock with small hammer. Tap steering lock pawl pin in until flush with housing.


6. Install lock lever spring and lock lever into housing using a drift to hold in place.

7. Install the other lever spring and lock lever with pin. Tap pin into place while driving out drift.


8. Support steering actuator housing in a vise and drive lock lever pin flush with steering actuator housing.


9. Place two nuts or spacers to hold steering column locking levers away from steering actuator housing.


10. Note: Lube pivot bolts with Ignition Lock Grease F0AZ-19584-A or equivalent meeting Ford specification ESA-M1C232-A before installing.

Position steering column position spring on steering column lock cylinder housing. With assistant, install steering actuator housing and pivot bolts. Tighten to 18-26 N-m (14-19 lb-ft).


11. Install steering column bearing tolerance ring and steering column bearing sleeve over steering shaft to upper steering column bearing (3517).


12. Install steering column upper bearing spring and new bearing retainer on top side of bearing spring using a 3/4-inch I.D. by 2-1/2-inch long PVC pipe.


13. Install turn indicator cancel cam, flush surface up.


14. Install ignition switch. Align pin from ignition switch with slot in lock/column assembly. Position slot in lock/column assembly with index mark on casting. Ignition switch should be in RUN position.

15. Tighten two retaining screws to 5-7 N-m (44-62 lb-in).

16. Install steering column lock gear. Coat steering column lock gear with Ignition Lock Grease F0AZ-19584-A or equivalent meeting Ford specification ESA-M1C232-A.

17. Lubricate steering column lock housing bearing. Lubricate with Ignition Lock Grease F0AZ-19584-A or equivalent meeting Ford specification ESA-M1C232-A. With actuator rack in 12 o'clock position, position steering column lock housing bearing with tang inboard and in 5 o'clock position in steering column lock cylinder housing. Insert tip of a screwdriver into double-D slot of steering column lock housing bearing, then turn counterclockwise 90 degrees.

18. Install plastic bearing retainer.


19. Install transmission column shift selector tube (column shift only). Coat gearshift lever socket bushing (7335) with Ignition Lock Grease F0AZ-19584-A or equivalent meeting Ford specification ESA-M1C232-A. Tighten screws to 7-11 N-m (62-97 lb-in).

20. Install transmission shift selector position insert and shift lock actuator.

21. Install steering column in vehicle.

22. Install air bag sliding contact (14A664), if so equipped.

23. Install steering wheel.

24. Install driver side air bag module (043B13), if so equipped, to steering wheel.

25. Connect battery ground strap and air bag backup power supply, if so equipped.

26. Verify air bag warning indicator, if so equipped.

 

To replace the interlock pin in my 93 column, I didn't need to remove the steering wheel. I did have to wiggle things to get the ignition lock mechanism (after the actual lock is removed of course) to free up so I could pull the pin out into the ignition lock housing area. I used bent, needlenose pliars.

 

dang. i forgot about the change in columns from the 87-88 to the 92-93 model year. the early ones are a pita to do, but i never did a newer one. so if fred says they are a piece of cake, i will take his word, cause to me, his hard jobs are easy.


unless he is doing another one of his electronic "toys". then i am out of my league.