Idnition switch will not turn to lock position if battery is connected. disconnect negative cable then lock cylinder works.

the manuals says

1. Rotate the lock cylinder key to the Lock position. Disconnect the negative battery cable from the battery.
2. For tilt column only, remove the upper extension shroud by squeezing it at the 6 and 12 o'clock positions and popping it free of the retaining plate at the 3 o'clock position.
3. Remove the 2 trim shroud halves by removing the 2 attaching screws.
4. Disconnect the ignition switch electrical connector.
5. Drill out the break-off head bolts connecting the switch to the lock cylinder housing by using a 1/8 in. (3mm) drill bit.
6. Remove the 2 bolts, using an Ex-3 Easy-out® tool or equivalent.
7. Disengage the ignition switch from the actuator pin.

The ignition switch on Mercury Sable is integrated into the ignition cylinder. When this switch fails, you may need to purchase a special switch from a Ford dealership if the switch used a wireless transponder.


Instructions for NON Functional Cylinder (Cylinder will Not Turn or No Keys ):
1. Disconnect the negative battery cable.
2. Remove the steering wheel.
3. Using locking pliers, twist the cylinder cap until it separates from the lock cylinder.
4. Using a 3/8 in. (10mm) diameter drill bit, drill down the middle of the ignition lock key slot approximately 13/4 in. (44mm) until the lock cylinder releases from its breakaway base. Remove the lock cylinder and drill shavings from the lock cylinder housing.
5. Remove the retainer, washer, ignition switch and actuator. Thoroughly clean all drill shavings and other foreign materials from the casting.
6. Inspect the lock cylinder housing for damage from the removal operation. If the housing is damaged, it must be replaced.

To install:
1. Replace the lock cylinder housing, if damaged.
2. Install the actuator and ignition switch.
3. Install the trim and electrical parts.
4. Install the ignition lock cylinder.
5. Install the steering wheel.
6. Connect the negative battery cable, then check the lock cylinder operation.


Instructions for Functional Cylinder ( Cylinder will Turn with Key):
1. Disconnect the negative battery cable.
2. Turn the lock cylinder key to the RUN position.
3. Using a 1/8 in. (3mm) diameter wire pin or a small drift, depress the lock cylinder retaining pin through the access hole in the upper steering column shroud (under the ignition lock cylinder) while pulling out on the lock cylinder. Remove the lock cylinder from the column.

To install:
1. Install the lock cylinder by turning it to the RUN position and depressing the retaining pin. Insert the lock cylinder into its housing. Make sure the cylinder is fully seated and aligned in the interlocking washer before turning the key to the OFF position. This will permit the cylinder retaining pin to extend into the cylinder housing.
2. Rotate the lock cylinder using the lock cylinder key, to ensure correct mechanical operation in all positions.
3. Connect the negative battery cable.


Door Lock:
When a lock cylinder must be replaced, replace both sides as a set to avoid carrying an extra set of keys.
1. Remove the door trim panel and watershield.
2. Remove the clip attaching the lock cylinder rod to the lock cylinder.
3. Pry the lock cylinder out of the slot in the door.


To install:
1. Work the lock cylinder assembly into the outer door panel.
2. Install the cylinder retainer into the slot and push the retainer onto the lock cylinder.
3. Connect the lock cylinder rod to the lock cylinder and install the clip. Lock and unlock the door to check for proper operation.
4. Install the watershield and door trim panel


Hope this helps.

you will find clear pictures here;
http://www.stolenandrecovered.com/index.php



Ignition Switch & Lock Cylinder

• REMOVAL & INSTALLATION

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
3. Remove or disconnect the following:
   
   Steering column upper and lower covers Key ring antenna Steering lock cylinder
   
4. Insert the key in the steering lock cylinder and turn it to the "ACC" position.
5. Using a small Phillips head screwdriver, pull the steering lock cylinder toward you.

To install:

1. Install or connect the following:
   
   Ignition switch to steering column Steering lock cylinder to ignition switch Key ring antenna to ignition switch Steering column upper and lower covers
   

Ignition Switch - REMOVAL & INSTALLATION
(see Figure 1)

1. Disconnect the negative battery cable.
2. Remove the lower column trim panel, then remove the steering column-to-instrument panel fasteners and carefully lower the column for access to the switch.
3. Place the ignition switch in the OFF-LOCK position.
   

If the lock cylinder was removed on vehicles through 1991, the actuating rod should be pulled up until it stops, then moved down one detent; the switch is now in the Lock position.

Fig. 1: Adjusting the ignition switch

1. Remove the ignition switch-to-steering column retainers, then remove the assembly.
   

To install:

1. Before installing the ignition switch, place it in the OFF-LOCK position, then make sure that the lock cylinder and actuating rod are in the Locked position (1st detent from the top or 1st detent to the right of far left detent travel).

Most replacement switches are pinned in the OFF-LOCK position for installation purposes. If so, the pin MUST be removed after installation or damage may occur.

1. Install the activating rod into the ignition switch and assemble the switch onto the steering column. Once the switch is properly positioned, tighten the ignition switch-to-steering column retainers to 35 inch lbs. (4.0 Nm).
   

When installing the ignition switch, use only the specified screws since over length screws could impair the collapsibility of the column.

1. Raise the column into position and secure, then install any necessary trim plates.
2. Make sure the ignition is OFF , then connect the negative battery cable.

Ignition Lock Cylinder - REMOVAL & INSTALLATION
(see Figure 1)

1. Disconnect the negative battery cable.
2. Matchmark and remove the steering wheel.
3. Remove the turn signal switch from the column and allow it to hang from the wires (leaving them connected). For details, please refer to the procedure located earlier in this section.
4. For vehicles through 1991, place the lock cylinder in the Run position.
5. For 1992-93 vehicles, remove the buzzer switch assembly.
   

Fig. 1: Ignition cylinder replacement

1. Carefully remove the lock cylinder screw and the lock cylinder. If possible, use a magnetic tipped screwdriver on the screw in order to help prevent the possibility of dropping it.

CAUTION If the screw is dropped upon removal, it could fall into the steering column, requiring complete disassembly in order to retrieve the screw and prevent damage.
To install:

1. Align and install the lock cylinder set. On vehicles through 1991 it will be necessary to rotate the switch clockwise to align the cylinder key with the keyway in the housing.
2. Push the lock cylinder all the way in, then carefully install the retaining screw. Tighten the screw to 22 inch lbs. (2.5 Nm) on tilt columns or to 40 inch lbs. (4.5 Nm) on standard non-tilt columns.
3. If necessary, install the buzzer switch assembly.
4. Reposition and secure the turn signal switch assembly
5. Align and install the steering wheel.
6. Make sure the ignition is OFF , then connect the negative battery cable.

Keep us updated about your advance.

Ignition Lock Cylinder REMOVAL & INSTALLATION Functional Lock The following procedure applies to vehicles that have functional lock cylinders. Such cylinders either have a key available or known key numbers from which a key can be made.

1. Disconnect the negative battery cable.
2. Turn the lock cylinder key to the RUN position.
3. Using a 1?8 in. (3mm) diameter wire pin or a small drift, depress the lock cylinder retaining pin through the access hole in the upper steering column shroud (under the ignition lock cylinder) while pulling out on the lock cylinder. Remove the lock cylinder from the column. Fig. 1: Using the key, turn the ignition lock cylinder to the RUN position, then depress the retaining pin using a wire pin or small drift
   To install:
   
4. Install the lock cylinder by turning it to the RUN position and depressing the retaining pin. Insert the lock cylinder into its housing. Make sure the cylinder is fully seated and aligned in the interlocking washer before turning the key to the OFF position. This will permit the cylinder retaining pin to extend into the cylinder housing.
5. Rotate the lock cylinder using the lock cylinder key, to ensure correct mechanical operation in all positions.
6. Connect the negative battery cable.

Non-Functional Lock The following procedure applies to vehicles in which the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken key, unknown key number or a lock cylinder cap that has been damaged and/or broken to the extent that the lock cylinder cannot be rotated. 1986-90 VEHICLES

1. Disconnect the negative battery cable.
2. Remove the steering wheel. For details, please refer to the procedure located earlier in this section.
3. Remove the two trim shroud halves after removing the three attaching screws.
4. Disengage the electrical connector from the key warning switch.
5. Using a 1?8 in. (3mm) diameter drill, carefully drill out the retaining pin, being careful not to drill deeper than 1?2 in. (13mm).
6. Place a suitable chisel at the base of the ignition lock cylinder cap, then, using a suitable hammer, strike the chisel with sharp blows to break the cap away from the lock cylinder.
7. Using a 3?8 in. (10mm) diameter drill, carefully drill down the middle of the ignition key slot approximately 1 3?4 in. (44mm) until the lock cylinder breaks loose from its breakaway base. Remove the lock cylinder and drill shavings from the lock cylinder housing.
8. Remove the retainer, washer, ignition switch and actuator. Thoroughly clean all the drill shavings from the casting.
9. Inspect the lock cylinder housing for damage from the removal operation. To install:
   
10. Replace the lock cylinder housing if it was damaged.
11. Install the actuator and ignition switch.
12. Install the trim and electrical parts.
13. Install a new ignition lock cylinder.
14. Install the steering wheel. For details, please refer to the procedure located earlier in this section.
15. Connect the negative battery cable.
16. Check the lock cylinder operation.

1991-95 VEHICLES

1. Disconnect the negative battery cable.
2. Remove the steering wheel.
3. Using locking pliers, twist the cylinder cap until it separates from the lock cylinder.
4. Using a 3?8 in. (10mm) diameter drill bit, drill down the middle of the ignition lock key slot approximately 1 3?4 in. (44mm) until the lock cylinder releases from its breakaway base. Remove the lock cylinder and drill shavings from the lock cylinder housing.
5. Remove the retainer, washer, ignition switch and actuator. Thoroughly clean all drill shavings and other foreign materials from the casting.
6. Inspect the lock cylinder housing for damage from the removal operation. If the housing is damaged, it must be replaced. To install:
   
7. Replace the lock cylinder housing, if damaged.
8. Install the actuator and ignition switch.
9. Install the trim and electrical parts.
10. Install the ignition lock cylinder.
11. Install the steering wheel.
12. Connect the negative battery cable, then check the lock cylinder operation.

IGNITION LOCK CYLINDER AND SWITCH

Removal Procedure

1. Disconnect the negative battery cable
2. Remove the lower steering column cover panel by removing the screws.
3. Disconnect the electrical connector for the immobilizer detection coil, if equipped.
4. With the key in the ignition turned to the position designated ACC, remove the lock cylinder by pressing down the detent spring with a 2.5 mm alien wrench or other suitable tool, and pulling the lock cylinder out of the switch cylinder housing. 5. Install the lower steering column cover panel with the screws. Tighten the lower steering column cover panel screws to 3 Nm (27 inch lbs.).
5. Connect the negative battery cable

• Ignition Removal Instructions
  
• Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

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• Remove the upper and lower shrouds. Refer to Steering Column Trim Covers - Disassemble - Off Vehicle or Steering Column Trim Covers - Disassemble - Off Vehicle .

• Put the key in the steering column lock cylinder set (1).

• Turn the key to the "START" position.

• Install a 1/16 allen wrench (2) into the hole on top of the lock module assembly in order to release the steering column lock cylinderset retaining pin.

• Turn the steering column lock cylinder set (1) into the "RUN" position.

• Pull the steering column lock cylinder set (1) out from the lock module assembly.

• Remove the key from the steering column lock cylinder set (1).
  

• Installation Instructions

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• Insert the key into the steering column lock cylinder set (1).
• LIne up the locking tab (2) and the positioning tab (3) of the steering column lock cylinder set with the locking tab slot (5) and the positioning tab slot (4) in the lock module assembly (6).
• Push the steering column lock cylinder set (1) into the lock module assembly (6).
• Rotate the steering column lock cylinder set (1) in the lock module assembly (6) into all positions.
• Install the upper and lower shrouds. Refer to Steering Column Trim Covers - Assemble - Off Vehicle or Steering Column Trim Covers - Assemble - Off Vehicle
• Remove the ignition key from the lock cylinder set (1).
• Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical

I hope this helps and good luck.
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PATH: Chassis Electrical > Instruments & Switches > Ignition Switch > Removal & Installation Removal & Installation

1. Disconnect the negative battery cable.
   
2. Disable the airbag system, as outlined in the Chassis Electrical Section.
   
3. Remove the hush and knee bolster.
   
4. Remove the steering column trim covers.
   
5. With the key installed, turn the key to the RUN position.
   
6. Install a hex wrench into the hole on top of the lock cylinder housing. Push down on the hex wrench to release the tab on the lock cylinder inside the lock cylinder housing.
   

Push down on the hex wrench to release the tab on the lock cylinder inside the lock cylinder housing

1. Slide the lock cylinder out of the lock cylinder housing.
   
2. Disconnect the passlock and key buzzer from the lock cylinder housing.
   
3. Insert into the lock cylinder housing
   

Release the tabs on the ignition switch using ignition switch connector release tool J 42759

1. Pull the ignition switch out of the lock cylinder housing.
   
2. Disconnect the connector from the ignition switch.
   

To install:

1. Verify the alignment of the gear in the ignition switch. If gear is not in position shown, turn gear in ignition switch until you reach the correct position.
   
2. Use a screwdriver to rotate the lock cylinder housing gear counterclockwise until it hits a stop. In order to reach a stop while rotating the lock cylinder housing gear you MUST push and hold in the solenoid on the electric park lock.
   
3. Connect the connector to the ignition switch.
   
4. Insert the ignition switch into the lock cylinder housing. The tabs on the ignition switch MUST be seated inside the lock cylinder housing for proper installation.
   
5. Use a screwdriver to rotate the lock cylinder housing gear clockwise to the start position—allowing it to spring return into the RUN position.
   

Use a screwdriver to rotate the lock cylinder housing gear clockwise to the START position

1. Align the lock cylinder and install the lock cylinder into the lock cylinder housing.
   
2. Connect the passlock and key buzzer into the lock housing.
   
3. Install the steering column trim covers.
   
4. Install the hush and knee bolster.
   
5. Enable the airbag system, as outlined in the Chassis Electrical Section.
   
6. Connect the negative battery cable.
   

If the vehicle is not equipped with an air bag, skip Step 1 and simply disconnect the negative battery cable. Also, disregard all instructions below related to air bags.

1. If equipped, disable the SIR system, as outlined in Section 6 of this manual.
   
2. If not already done, disconnect the negative battery cable.
   
3. Remove the turn signal switch assembly.
   
4. Remove the key from the lock cylinder. Remove the buzzer switch and clip.
   
5. Reinsert the key into the lock cylinder and turn it to the LOCK position.
   
6. Remove the cylinder lock-to-steering column screw, then remove the lock set.
   
7. If equipped, detach the pass key connector.
   

To install:

1. Install the lock cylinder, attach the pass key connector (if equipped), then tighten the lock-to-steering column screw to 22 inch lbs. (2.5 Nm).
   
2. Position the key in the RUN position and reverse the removal procedures.
   
3. Install the turn signal switch.
   
4. If equipped with the SIR system, properly enable the system, as outlined in Section 6 of this section.
   
5. If not already done, connect the negative battery cable, then check the turn signals for proper operation.
   

Grand Am 3.1 liters REMOVE Negative battery cable. Air bag fuse. Lower left insulator panel (3) screws. Disconnect 2-way yellow SIR connectors (2). Tilt lever. Upper and lower steering column trim cover. Turn lock cylinder to run position. Push against locking button on back side of bearing and housing assembly and remove lock cylinder. INSTALL Lock cylinder to housing assembly. CAUTION : Rotate the lock cylinder to the "RUN" position. Depress the lock cylinder button. Gently push the lock cylinder into place while rotating the key approximately 5°in the counter-clockwise direction. Upper and lower column cover (3) Torx(R) screws. Tilt lever. Connect 2-way yellow SIR connections (2). Lower left insulator panel (3) screws. Air bag fuse. Negative battery cable.