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66-96 Ford Broncos - Early & Full Size
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Ignition Switch Adjustment Proceedure

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The following proceedure is from the 1983 Ford Service manual, with a few minor wording changes, but should work for any year. Also included are a couple of illustrations from the same proceedure to help you visualize it.

 

1. Remove the electrical connector from the ignition switch.

 

2.Rotate the key back and forth to either side of LOCK, until a 5/64 in. drill bit can be inserted through the locking pin hole as far as possible (minimum 3/8 inch). The lock pin hole is located on the right of the switch next to the steering column tube.

 

3. Loosen the two ignition switch mounting nuts.

 

4. Turn the key to LOCK (feel for detent) and remove the key.

 

5. move the switch up and down along the column to locate the mid-positionof rod lash and tighten the mounting nuts.

 

6. Remove the drill bit from the ignition switch lock pin hole.

 

7. Plug in the electrical connector and operate the lock cylinder to insure the switch is positioned properly.

 

8. Confirm that all accessories are deactivated with key on the OFF position, and that all accessories are operable in RUN position.

 

Good luck,

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Ignition Switch Removal & Installation in a 96 from 1996 F-150, F-250, F-350, F-Super Duty, F-Super Duty Motorhome and Bronco Workshop Manual; same as 92 through 95 and possibly earlier years. 
"... Ignition Switch

Removal
Disconnect battery ground cable (14301). Remove the upper steering column shroud (3530) by removing the self-tapping screws.

Remove four bolts retaining lower steering column shroud and remove lower steering column shroud.

Remove lock screw and disconnect the ignition switch electrical connector.

Rotate the ignition switch lock cylinder (11582) to the RUN position.

Remove the two screws retaining ignition switch (11572).

Disengage the ignition switch from the actuator.

Installation

NOTE: A new replacement ignition switch assembly will be set in the RUN position as received.

Adjust the ignition switch by sliding the carrier to the RUN position.

Make sure the ignition switch lock cylinder is in the RUN position. The RUN position is achieved by rotating the ignition switch lock cylinder approximately 90 degrees from the LOCK position.

Install the ignition switch into the column actuator hole. It may be necessary to move the ignition switch back and forth slightly to align the ignition switch mounting holes with the lock cylinder housing threaded holes.

Install retaining screws. Tighten to 6-8 Nm (53-71 lb-in).

Connect the electrical connector to the ignition switch. Tighten lock screw to 0.8-1.3 Nm (7-11.5 lb-in).

Connect battery ground cable. Check ignition switch for proper function, including START and ACC positions. Also, make certain that the column is in the LOCK position.

Install the upper steering column shroud and lower steering column shroud."

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