I am in the process of refurbishing a 69 that the previous owner had bypassed the ignition system and wired the starter to a toggle switch in the dash. I have replaced the lock cylinder and the ignition switch itself. The problem comes in when I try to hook up the pushrod that activates the ignotion switch. It has to be twisted clockwise about a half of a turn to go into the switch and then it is so hard to turn the key that I am afraid I will break the key off or something. Any ideas, suggestions or solutions?? Thanks for any help.

Mike

This may sound dumb, but do you have the right end of the rod on the switch?

You don't mention it, but I assume that you have a standard (non-adjustable) steering column.

It sounds as if you are doing everything correctly. The following is taken from my paper on disassembly and repair of the Saginaw steering column.
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ASSEMBLE IGNITION SWITCH
In order to correctly install the ignition switch it is necessary for the lock cylinder to be installed in the column and placed in the “Off Unlock” position.

On all columns, reach down to the lower column lever and move it down to its lowest position. Now rotate the lock cylinder all the way counterclockwise until it stops. This will be the “Off Unlock” position.

You should have removed the ignition switch in the “Off-Unlock” position. However, if you are in doubt that it is correct, proceed as follows:
Move the slider inside the ignition switch all the way to the end of travel (“Accessory”) where it should detent and stay in that position. If in doubt, the other extreme will be the "Start" position and you will feel a spring return. Now move the slider two detent positions back from the “Accessory” position.

Fit the actuator rod into the slider hole and assemble it to the column with the two screws. Lightly push the switch down the column (away from the steering wheel), to take out lash in the actuator rod, and tighten the mounting screws. Caution should be exercised to prevent moving the switch out of the “Off-Unlock” detent. Tighten the screws to 35 in-lbs.
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Does the rod move smoothly when it is not hooked into the ignition switch? Are you sure that you have the correct switch?

BTW More of my papers disassembly and repair of Saginaw Steering Gear parts can be found at:
www.corvettefaq.com/A-car.asp (http://www.corvettefaq.com/A-car.asp)

I am almost certain I have the right end of the rod. It is the end that came out of the old switch. The new switch is slightly different from the old one but not enough to make any difference with the rod and the rod does move freely when not inserted into the switch. (and yes it is just a standard steering column.) I'll check out the web link and see if I might see or read something that looks like I am doing wrong. Thanks guys.

Do you have a tilt or non tilt column?? The ignition switches are different and so is the length of the rod that goes down to them. It sounds to me like you have the wrong ignition switch.

try here for your answers:
http://www.camaros.net/techref/articles/ftecref011.html


this got the correct lock replacement procedures