Steering Column Repair: 2004 express van starting problem, plastic gears, column shifter

Question
2004 express van.  Few months back steering wheel would not unlock with key in, key would not turn, shifter would not move.  Pulled wheel left/right, no success.  eventually turned ignition switch with pliers.  Problem is now van occansionally won't start but key turns.  After wiggling steering wheel, beating on top and bottom of column, moving shifter between all settings, turning key switch several times, it would catch and start.  No problems for several days, then happens again.  I have taken the column apart looking for something broken, but cannot find anything.  Did I break something in the column/shifter lock system?  Is the ignition switch bad?

Answer
Hello Phillip:

Without actually feeling what the key and ignition feels like when you turn to start it, it's hared for me to say for sure.  but there are 2 things that are common on that design.  the ignition switch itself (the electrical part with the wire harness) goes bad often.  the other thing is the ignition lock cylinder case.  That is the part the lock goes into.  It has plastic gears inside the shatter.  Since there is no place for the pieces to go when the gears shatter, because they are stuck in place, they work  intermittently, sometimes meshing perfectly and sometimes skipping a tooth.
Either way, you are going to spend between $150 and $250 to replace either of these parts and the only way to know for sure is to take i apart and see what is broken (or shorted).

I hope this helps

Doug