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Steering Column Ignition Puzzle I can't solve

GaBnn3

1/2 ton status
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Joined
Jan 2, 2005
Posts
185
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Location
Holyoke, Ma.
I had a steering column issue several months ago in my '91 V2500 Burb. The outer shift housing rotated beyond it's intended range and the ignition cylinder became stuck in the on position, so I had to pull the distributor wire to shut it off. It always had the loose screws in the lower tilt housing common to these models, so I concluded that one of those screws had come loose and jammed the ignition rod or other internal parts preventing the cylinder from rotating properly. Thus, I took my die grinder to the outer shift housing to get in and fix the problem. There was no jam from any screw or loose part inside the column so I concluded there was a problem with the ignition cylinder. However cutting into the outer shift housing necessitated a rebuild of the column, which I did. Along the way I discovered a broken shift gate which explained why the shift housing rotated beyond it's range. Ultimately fixed that. But the ignition cylinder was still stuck in the on position. I sat in the driver's seat and kept attempting to turn the ignition cylinder. After about 25 tried the cylinder released and I was able to get on with the project. I don't see how the two issues could be related and believed it to be an unlucky coincidence. I replaced the ignition cylinder, thinking all problems were fixed. However, now on my rebuilt column I can not rotated the ignition cylinder to the start position. It will go as far as on but no further. I had not replaced the ignition switch. So, I thought that may be the issue. I replaced the ignition switch but that did not fix the problem. Now I wonder if there is a problem with the ignition housing. But I hate to throw money replacing random parts without knowing what is going on. I already needlessly cut open the shift collar. Has anyone else encountered this problem? And suggestions would be appreciated. Thanks.
 
If you disconnect the ignition rod from the switch at the base of the column, does the cylinder rotate far enough? If it does, check the adjustment on the switch at the base of the column. You should also be able to start the truck using just the switch to check that it is not broken. I drove a truck for months after getting it back from being stolen, by starting it with just the switch.
 
I would be looking to see if the rack and pinion inside the upper housing skipped or is just off a tooth. What I am referring to is what actuates the rod going to the ignition switch. The pinion gear is turned by the ignition lock.
( You may know this, but I am just covering bases here.)

Also, did you look to confirm that the ignition switch didn't come loose and slide out of adjustment?
 
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