Ignition key will not work.

No. The ignition switch is located farther down on the steering column. The lock cylinder rotates and move an actuator rod. The rod move up or down and slides the contacts in the switch. Pull the trim panels below the steering column and look for the switch screwed onto the column itself. Just follow the wires.

Check to see that the cylinders are exactly the same.
Try replacing and removing the original.

The ignition key must be in the key cylinder for cylinder removal. The key cylinder must be removed first before removing ignition switch.REMOVAL 1. Disconnect negative battery cable at battery. 2. If equipped with an automatic transmission, place shifter in PARK position. 3. Rotate key to ON position.4. A release tang is located on bottom of key cylinder.5. Position a small screwdriver or pin punch into tang access hole on bottom of steering column lower cover.INSTALLATION 1. If equipped with an automatic transmission, place shifter in PARK position. 2. Position key cylinder into steering column as it would normally be in the ON position. 3. Press key cylinder into column until it snaps into position. 4. Check mechanical operation of switch. Automatic Transmission: Be sure transmission lever is locked in PARK position after key removal. If key is difficult to rotate or is difficult to remove, the shift lever-to-steering column cable may be out of adjustment or defective. If key can be removed, release lever mechanism may be defective. Release lever mechanism is not serviced separately. If repair is necessary, the steering column must be replaced. 5. Connect negative cable to battery. 6. Check electrical operation of switch.

Ignition and Start Switch Replacement
Removal Procedure
Disconnect the battery ground cable. .
Remove the steering column filler panel.
Remove the knee bolster bracket.
Remove the instrument panel (I/P) cluster trim panel.
Remove the ignition switch bolts.
Lower the ignition switch away from the instrument carrier.
Insert the key into the ignition lock cylinder. Turn the key to the ON/RUN position.
Depress the transaxle park/lock cable retainer to release. Pull to remove the park/lock cable from the ignition switch.
Important: The Passlock? electrical connector cannot be removed until the lock cylinder is removed.

Depress and hold the detent on the bottom of the ignition switch in order to release the ignition lock cylinder. Remove the ignition lock cylinder with the key.
Disconnect the Passlock? electrical connector.
Disconnect the electrical connectors.
Important: Ignition switch lock cylinder that won't rotate or is seized.

Perform the following procedure if the ignition switch lock cylinder is seized or won't rotate.
12.1. Protect the immediate work area with suitable material such as clean shop towels or a clean fender cover.

12.2. Locate the surface for the ignition switch lock cylinder release button (2) on the plastic ignition switch housing and center punch a location (1) on the "rib" approximately 3/8 inch reward (toward the key entry end) from the cylinder release button.

12.3. Carefully drill a hole through the plastic housing with a 1/8 inch drill bit.

12.4. Carefully drill a larger hole at the pilot location, and slightly into the ignition switch lock cylinder surface to break the release button retaining spring using a 9/32 inch drill bit.

12.5. Remove portions of the broken spring from the hole using a small suitable tool.

12.6. Grasp the ignition switch lock cylinder and remove it from the switch housing.

12.7. Remove any plastic "flash" from the drilling operation, and using compressed air blow out the ignition switch assembly.

12.8. Follow service manual procedures when cylinder cording is required. Refer to Key and Lock Cylinder Coding in General Information.

Installation Procedure
If the lock cylinder would not rotate or was seized, perform the following procedure:
1.1. Install the new ignition switch lock cylinder as required by rotating both the cylinder and the ignition switch to the ON position.

1.2. Push the ignition switch lock cylinder into the ignition switch housing until fully seated.

1.3. You may have to slightly depress the release button as the button passes by the 9/32-in hole previously drilled in the ignition switch housing.
Connect the electrical connectors.
Connect the Passlock? electrical connector.
Connect the park/lock cable to the ignition switch Turn the key to the ON/RUN position. Install the ignition lock cylinder into the ignition switch. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger.
Remove the key
Position the ignition switch to the instrument carrier.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Install the ignition switch bolts.
Tighten

Tighten the bolts to 10 N?m (89 lb in).

Install the trim plate bezel to the I/P cluster. Refer to Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster .
Install the knee bolster bracket. Refer to Bracket Replacement - Knee Bolster .
Install the steering column filler panel. Refer to Steering Column Filler Replacement .
Connect the battery ground cable. Refer to Battery Negative Cable Disconnect and Connect Procedure in Engine Electrical.

1. Disable air bag system.
2. Remove steering column shroud by removing self-tapping screws. Remove tilt lever if equipped.
3. Remove instrument panel lower steering column cover.
4. Disconnect ignition switch electrical connector.
5. Rotate ignition key lock cylinder to RUN position, then remove two screws retaining ignition switch.
6. Disconnect ignition switch from actuator.
7. Reverse procedure to install, noting the following:

1. If necessary, move switch slightly back and forth to align mounting holes with column mounting holes.
2. Activate air bag system.
3. Ensure proper operation of ignition switch in all positions.

Hope this helps you! Please don't forget to rate....thanks!!



Ignition switch installation-1984-90 models

1. Disconnect the negative battery cable.
   
2. Remove the steering column cover.
   
3. If equipped with automatic transaxle, position the gear selector into DRIVE and disconnect the indicator cable.
   
4. Remove the lower panel reinforcement.
   
5. Drop the steering column for switch replacement.
   
6. Disengage the wiring connector from the ignition switch.
   
7. Position the ignition lock cylinder into the LOCK position.
   
8. Tape the ignition switch rod to the steering column to prevent the rod from falling out of the lock cylinder assembly.
   
9. Remove the screws attaching the ignition switch to the column jacket.
   
10. Remove the ignition switch by rotating the switch 90 degrees and pulling up to disengage from the rod.
    

To install:

1. Rotate the switch 90° and push down to engage the rod.
   
2. Install the screws to the ignition switch mounting plate but do not tighten.
   
3. Remove the tape holding the rod to the column.
   
4. Adjust the switch by pushing up on the switch to take up rod system slack. This must be done with the key cylinder in the LOCK position and the key removed.
   
5. Tighten the screws attaching the switch to the column.
   
6. Connect the wiring connector to the ignition switch.
   
7. Install the steering column.
   
8. Install the steering column cover.
   
9. Connect the negative battery cable.
   

this is the oldest info I have. should be similar

Section 11-05: Steering Column Switches 1994 Town Car, Crown Victoria/Grand Marquis. Workshop Manual
REMOVAL AND INSTALLATION Ignition Switch Removal

1. Disconnect battery ground cable. Remove the upper steering column shroud by removing the four or five self-tapping screws. Remove tilt steering column lock lever (if so equipped).

1. Remove lower steering column shroud.

1. Disconnect the ignition switch electrical connector.

1. Rotate ignition switch lock cylinder to the RUN position.

1. Remove the two screws retaining ignition switch.

1. Disengage the ignition switch from the actuator.

Installation
NOTE: A new replacement ignition switch assembly will be set in the RUN position as received.

1. Adjust the ignition switch by sliding the carrier to the ignition switch RUN position.

1. Check to ensure 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 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 upper steering column shroud.

1. Install the lower steering column shroud and tilt steering column lock lever (if so equipped).

Not an exact solution, but perhaps information that might lead to one.

1.Replaced the tumblers? I believe I would replace the entire ignition switch this time. It's my belief that the body of the ignition switch is worn inside, and will keep damaging the tumblers.

2.Do you have a tilt steering wheel? It's best to keep the steering column in straight line when starting the car, then tilt the wheel to where you want, after the car is started. When the steering column is in a tilted position, it puts undue strain on the ignition key switch, and the mechanism the ignition key switch operates, on GM vehicles.

This mechanism, consists of a half moon gear on the ignition key switch, that turns inside a 'Planetary' gear. I used the term 'Planetary', as the gear shape is hard to describe. It resembles an oblong loop, shaped like the number 9, with gear teeth on the inside bottom of the loop. This 'Loop' rotates, when the gear teeth of the ignition key switch, engage the teeth on the loop, and pushes a rod, or retracts the rod. The rod goes down the side of your steering column, and turns on, or turns off an ignition switch, located at the bottom left side of the steering column.

Having the steering wheel tilted, puts a strain on the ignition key switch internals, the oblong loop can break, and/or gear teeth can be stripped off.

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.

Ignition and Start Switch Replacement
Removal Procedure
Disconnect the battery ground cable. Refer to Battery Negative Cable Disconnect and Connect Procedure in Engine Electrical.
Remove the steering column filler panel. Refer to Steering Column Filler Replacement .
Remove the knee bolster bracket. Refer to Bracket Replacement - Knee Bolster .
Remove the instrument panel (I/P) cluster trim panel. Refer to Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster .
Remove the ignition switch bolts.
Lower the ignition switch away from the instrument carrier.
Insert the key into the ignition lock cylinder. Turn the key to the ON/RUN position.
Depress the transaxle park/lock cable retainer to release. Pull to remove the park/lock cable from the ignition switch.
Important: The Passlock? electrical connector cannot be removed until the lock cylinder is removed.

Depress and hold the detent on the bottom of the ignition switch in order to release the ignition lock cylinder. Remove the ignition lock cylinder with the key.
Disconnect the Passlock? electrical connector.
Disconnect the electrical connectors.
Important: Ignition switch lock cylinder that won't rotate or is seized.

Perform the following procedure if the ignition switch lock cylinder is seized or won't rotate.
12.1. Protect the immediate work area with suitable material such as clean shop towels or a clean fender cover.

12.2. Locate the surface for the ignition switch lock cylinder release button (2) on the plastic ignition switch housing and center punch a location (1) on the "rib" approximately 3/8 inch reward (toward the key entry end) from the cylinder release button.

12.3. Carefully drill a pilot hole through the plastic housing with a 1/8 inch drill bit.

12.4. Carefully drill a larger hole at the pilot location, and slightly into the ignition switch lock cylinder surface to break the release button retaining spring using a 9/32 inch drill bit.

12.5. Remove portions of the broken spring from the hole using a small suitable tool.

12.6. Grasp the ignition switch lock cylinder and remove it from the switch housing.

12.7. Remove any plastic "flash" from the drilling operation, and using compressed air blow out the ignition switch assembly.

12.8. Follow service manual procedures when cylinder cording is required. Refer to Key and Lock Cylinder Coding in General Information.

Installation Procedure
If the lock cylinder would not rotate or was seized, perform the following procedure:
1.1. Install the new ignition switch lock cylinder as required by rotating both the cylinder and the ignition switch to the ON position.

1.2. Push the ignition switch lock cylinder into the ignition switch housing until fully seated.

1.3. You may have to slightly depress the release button as the button passes by the 9/32-in hole previously drilled in the ignition switch housing.
Connect the electrical connectors.
Connect the Passlock? electrical connector.
Connect the park/lock cable to the ignition switch Turn the key to the ON/RUN position. Install the ignition lock cylinder into the ignition switch. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger.
Remove the key
Position the ignition switch to the instrument carrier.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Install the ignition switch bolts.
Tighten

Tighten the bolts to 10 N?m (89 lb in).

Install the trim plate bezel to the I/P cluster. Refer to Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster .
Install the knee bolster bracket. Refer to Bracket Replacement - Knee Bolster .
Install the steering column filler panel. Refer to Steering Column Filler Replacement .
Connect the battery ground cable. Refer to Battery Negative Cable Disconnect and Connect Procedure in Engine Electrical.

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