I have a 2002 taurus. I removed the ignition lock cylinder but the gear came out with it. I need help on how to time the gear back into its proper setting.

Usually a sign the tumblers in the lock cylinder have worn out or jammed.
You may have to get the lock cylinder drilled out and replaced.

The steering wheel was turned when the key was removed. So when you try to turn on the key, turn the wheel one way and the other way to release the pressure on the key. The key should turn ok.
Hope this helps.

Don't you just hate when that happens? Your tumbler cylinder is not in time with your switch.

the actuator inside the sterring column that the lock cylinder turns is boken, this is a very complex job and is not for the home tech without a factory service manual.

I think you have a bad ignition switch, not the ignition lock cylinder. they are 2 different things.

Section 11-05: Steering Column Switches 1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION Ignition Switch Removal

1. Disconnect battery ground cable (14301).
   

1. Remove lower instrument panel steering column cover (04459).
   

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

1. Disconnect the ignition switch electrical connector.
   

1. Remove the two screws retaining ignition switch (11572).
   

1. Disengage the ignition switch from the actuator.
   

Installation

1. 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 ignition switch RUN position.
   

1. Make sure that 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.
   

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

1. Install retaining screws. Tighten to 5.6-7.9 Nm (50-69 lb-in).
   

1. Connect electrical connector to ignition switch.
   

1. 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.
   

1. Install lower instrument panel steering column cover with screws.
   

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.
   

It is not necessary to have the dealer do this, think of the cash! Though it does require patience and time. The pin you are supposed to push in goes into a slot when you have it in run position, since you cannot turn it to run you have to make a slot for the pin to go into, with a drill. Be very careful as you only have a 1/4" of play before you break a washer behind the cylinder. Once you have drilled out the key far enough to the pin hole you can take a nail set and tap the pin up, you can tell when the pin clears the housing, then it just takes wiggle, patience and tinkering to get the cylinder to slide out, keep the green washer and the metal slot washer. Metal slot washer goes in first with green plastic washer ontop of that with lock cylinder in last. You can play around with the new lock cylinder and washer before insertion to determin correct direction.

Here are official directions with inoperable lock cylinder. They say drill out retaining pin but it just spun in circles for me - I looked at new cylinder and saw how it worked. retaining pin needs a place to go.
Removal & Installation (Non-Functional)
NOTE:Use this procedure to remove ignition lock cylinder if key is missing or cylinder is frozen.

Disconnect negative battery cable. Disable air bag system. See appropriate AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS. Wait at least one minute for air bag back-up power supply to deplete. Remove steering wheel. See STEERING WHEEL . Using a 1/8" bit, drill out retaining pin located below lock cylinder on housing. DO NOT drill deeper than 1/2".
Using channel lock pliers, twist lock cylinder cap until it separates from lock cylinder. Using a 3/8" drill bit, drill down center of ignition lock key slot about 1 3/4" until lock cylinder breaks loose from its base.
Remove retainer, washer, and lock cylinder gear from housing. Remove metal shavings from lock cylinder bore. Replace housing if damaged. To install, reverse removal procedure. Connect negative battery cable. Check air bag system for proper system operation. See appropriate AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.

the ignition switch is an electrical part. The lock cylinder is whre the key goes and it activates the ignition switch. If you pulled the lock cylinder out, you could operate the car with a screwdriver.
Either you have damaged the ignition switch where the lock cylinder goes into it, or the lock cylinder is damaged where it fits into the ignition switch.

this is 96 taurus, don't have 92 sorry

Section 11-05: Steering Column Switches 1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION Ignition Switch Removal

1. Disconnect battery ground cable (14301).
   

1. Remove lower instrument panel steering column cover (04459).
   

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

1. Disconnect the ignition switch electrical connector.
   

1. Remove the two screws retaining ignition switch (11572).
   

1. Disengage the ignition switch from the actuator.
   

Installation

1. 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 ignition switch RUN position.
   

1. Make sure that 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.
   

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

1. Install retaining screws. Tighten to 5.6-7.9 Nm (50-69 lb-in).
   

1. Connect electrical connector to ignition switch.
   

1. 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.
   

1. Install lower instrument panel steering column cover with screws.
   

------------------
Section 11-05: Steering Column Switches 1996 Taurus, Sable Workshop Manual
DESCRIPTION AND OPERATION Ignition Switch The ignition switch (11572), which is mounted on the steering actuator housing (3F723), operates in the following manner:

• The ignition switch is cycled through rotation of the ignition switch lock cylinder (11582) through a pin which is part of the ignition switch.
• The ignition switch lock cylinder also controls the mechanism which provides a positive lock for the transaxle linkage and the steering system.
• The locking mechanism is located in the steering column housing.

The ignition switch lock cylinder positions are:

• ACC
• LOCK
• OFF
• RUN
• START

The key can be removed from the ignition switch lock cylinder with the column-shift transaxle only when the shift lever is in PARK position and the key is in LOCK position.

• The ACC position operates while the steering and transaxle remain locked.
• The engine shuts off when the key is turned to the OFF position without locking the steering or transaxle.

Blade Type
The ignition switch has blade-type terminals that engage with one multiple connector. The multiple connector is secured to the ignition switch by an integral connector fastener.

Lock Cylinder Functional
Removal

1. NOTE: The following procedure applies to vehicles that have functional ignition switch lock cylinders (11582), lock cylinder keys are available for these vehicles or the lock cylinder key numbers are known and the proper key can be made.
   
   Disconnect battery ground cable (14301). Refer to Section 14-01 .
   

1. Turn ignition switch lock cylinder to RUN position.
   

1. Place a 3.17 mm (1/8-inch) diameter wire pin or small drift punch in hole in lower steering column shroud (3530) under ignition switch (11572). Press retaining pin while pulling out on ignition switch lock cylinder to remove it from steering column lock cylinder housing (3511).
   

Installation

1. Install ignition switch lock cylinder by turning it to RUN position. Insert ignition switch lock cylinder into steering column lock cylinder housing. Make sure ignition switch lock cylinder is fully seated and aligned in interlocking washer before turning ignition switch lock cylinder to OFF position. This will permit cylinder retaining pin to extend into steering column tube flange hole.
   

1. Rotate ignition switch lock cylinder, using lock cylinder key, to ensure correct mechanical operation in all positions.
   

1. Connect battery ground cable.
   

Ignition Lock Cylinder
Ford Taurus/Sable 1986-1995 Repair Information





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.
   

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:

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.
   

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.