As many many ford truck owners have experienced before me, I was hit with the "my key turns but doesn't start the truck" syndrome. The symptoms are usually: key powers up the accessories, can turn all the way forward, but wont initiate the starter, and wont spring back the the "run" position.
After much fear inducing research, leading me to believe I needed to do a frame off resto just to replace a 14 dollar part, I came across this video of an alternate way to do it. And thank my lucky stars I did, because I did it in about 1.5 hours in 11 degree weather.
Anyway, I hope this helps anyone that is plagued with having to start their truck from under the hood.
How to fix the ignition switch on 1980 91 ford pickups with tilt steering Part 1 - YouTube
How to fix the ignition switch in 1980 91 ford pickups with tilt steering Part 2 - YouTube
watch parts 1 & 2. I just did this yesterday to mine and the method this guy does it is, by far and long, way easier than doing it the "propper" way.
The key cylinder engages the arm at the lowest point in the picture and "pushes" the arm down the column. this causes stress on the area I labeled "breaks here", and if its cold, it seems the stress is too much, so it breaks.
The piece is about 1/4 inch too long to get into the guide hole without taking the column apart, so if you break off the block at the end that i marked in blue it will fit with some minor finesse. However, as far as I can tell, the only thing the block at the end of the rod does is engage the interlock so you have to hit the button under the column to get the key out.
You need:
Phillips screwdriver, 15/16" socket, Steering wheel puller (can loan from parts store), Ford ignition actuator ($14+/-), needle nose pliers, regular pliers, and plenty of patients. (i broke one of the ears off to get the teeny tiny pin out instead of using a punch)
Watch the video and you should be able to get it no problem if you are at all mechanically inclined.
Disclaimer: I am NOT a mechanic. This may not be the BEST way to do it, and there may be a better alternative. This is just the way that I did it, and my truck is perfectly operational (also, I prefer not having to hit the switch to get the key out).
Good luck