'83 Ignition Switch/Key Cylinder Woes

[Bob Q]

I went to start my '83 K2500 this afternoon and when I turned the key to the Start position, I heard and felt a "pop" and then the starter didn't engage. Now, the key "clocking" is off and the it won't return all the way to Lock and it won't engage the starter either. The steering wheel is free though and not locked. I had noticed the key cylinder was getting a little stiffer when turning it in the Start position for a little while now, but I was a little slow on addressing it...now I have no choice. Does this sound like the rack and sector gear on the rod have broken or maybe the ignition switch on top of the column? This is a non-tilt column on an '83 with a manual transmission.

Thanks.

[Dead Parrot]

Are the rest of the lights and such working properly? Do the gauges do their thing when you turn the key to run?

It does sound like a sector gear/rack or ignition switch problem.

Before tearing into the column, do a quick check for blown wires and/or fusible links. A wire blowing apart violently can be felt and make a 'pop'. Would suck to tear apart the column only to discover everything inside is fine and it was an electrical issue elsewhere.

[Bob Q]

Yeah, the dash lights and glow plugs cycle like normal, but I can tell the key cylinder "clocking" is off. The key turns over further than normal, but won't engage the starter, plus it won't turn all the way back to the Lock position.

[old Rusty C10]

the ignition switch on the bottom of the column sounds like the culprit to me

[Bob Q]

I can still feel the "detents" of the different key positions like Off, On, and Start (even though the key doesn't fully turn in Start and engage the starter.

[Dead Parrot]

Sounds like the sector gear lost a tooth. Had that happen to me and everything but the starter worked. Tilt column. That last tooth is the one that moves things far enough to hit the start contacts in the ignition switch.

Also had the rack break a different time and nothing worked then except the column lock. At that time there was a company in OKC that specialized in steering column stuff. An on site service call was something like $70 plus parts. Seemed a bargain at the time. He knew the trick to getting the broken rack out and the new one in. Also knew the thing about the torx screws at the bottom of the column. Took him less then a hour to do the whole job.

[Bob Q]

Anyone know of any videos or instructions on how to R&R the rack and sector gear on a non-tilt column?

[RustyPile]

Originally Posted by Bob Q

Anyone know of any videos or instructions on how to R&R the rack and sector gear on a non-tilt column?

This information is all over the internet. Using the wrong terminology will yield bad results.. Try using this term... "how to disassemble a GM non-tilt steering column"........

[Bob Q]

Thanks guys.

[Getter-Done]

Here is one series of the Build on U tube videos.

The Algorithm will take over from there.

HOW TO EASILY REBUILD A STEERING COLUMN, PART 1...

[Bob Q]

Thanks!

[Bob Q]

I might be missing something, but I can't get the turn signal/lock cylinder housing free from the rest of the column. I removed the four bolts holding this housing in, but it won't budge. Are there any tricks to removing this section? This is a manual transmission truck with the release tab. Is there anything I'm missing with the key release tab to get the housing freed up? The turn signal switch, key cylinder, and ignition switch are all removed from the column.

[Bob Q]

I ended up getting it. I was trying to separate the turn signal/lock cylinder housing portion of the column from the rest of the column. I found that the manual transmission/non-tilt columns are different in that you have to remove the whole column housing and there are three screws on the underside that you have to remove to separate that section. You can't just remove the four screws and remove the turn signal/lock cylinder housing like on the automatic transmission columns. I got it all back together this morning and it's ready to hit the road. Thanks everyone for their help with this project.