steering column issues, (long and frustrating)

[Andrew Stauffer <andrew.stauffer@cannondale.com>]

Okay....I'm attempting to repair my nearly free 86 8v rocco. The ignition
lock cylinder, column switches etc were destroyed by someone attempting to
turn the wheel aggressively without inserting a key.  Much force was used,
all parts needed replacement.  I was able to remove the remnants, hotwire
the car, and get it to my garage.  So far so good.  

So a buddy with a parts rabbit offers me the cast aluminum ignition lock
cylinder/switch deal and a set of turnsignal/wiper switches from the rabbit.
Checking a few parts catalogs I have around, it looks like this will do the
job rather nicely.  I install  the parts, do a quick electrical function
check, everthing is working, so I go to install the steering
wheel.........and there just isn't enough of the splined  steering shaft
protruding from the whole assembly to get the steering wheel on.  The
splines on the steering wheel barely meet the splines on the shaft.  And it
won't go on.  

This should be relatively easy.  I've replaced these parts on several
Rabbits.  But it's turned into quite a chore.  I've retraced my steps half a
dozen times.  Same results every time.  There's a 6mm bolt that secures the
cast aluminum lock/ cylinder to the steering column.  It lines up with the
appropriate tab, suggesting this piece is correctly located on the column.  

 It's as if the steering column is too short,  but that hasn't changed.   Or
that the turn signal/wiper switches are too thick, but they're the same
"thickness" as what came off.  

I'm absolutely stumped, anyone got any suggestions on this? I know where
there's one in a junk yard, maybe I can get a good "show and tell" look
there, but it's not a pick n pull, so that might be tough.  

Please share your ideas with me!

And happy holidays!
Andrew Stauffer
Cannondale Purchasing
www.cannondale.com
andrew.stauffer@cannondale.com
ph. 814 623 4516
fax 814 623 8917



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