In order to diagnose your problem from long distance, I need you to confirm the following:
1. Do you know if the tilt column operated correctly when you got it? In other words, did it operate correctly with the original ignition lock cylinder?
2. Did your original lock cylinder and key work correctly in your standard (non-adjustable column)?
3. The positions for the ignition key are as follows:
START (The ignition switch spring pushes back to the ON or Run position).
ON (This position is detented in the switch).
OFF (Switch detent and you cannot remove ignition key).
OFF-LOCK (The column lock bolt engages the steering shaft and the key can now be removed).
ACCESSORY (You need to push in on the lock cylinder in order to rotate to this position.
4. You are sure that you can get to the OFF-LOCK position and remove the key but not to the ACCESSORY position.
5. When you say that with the ignition switch removed you cannot get to ACCESSORY, are you saying that when you rotate the ignition key all the way counterclockwise, you come to the end of travel and then you push in on the lock cylinder but it will not rotate any further?
6. There is a backdrive cable from the transmission that connects to a lever on the lower end of the steering column (right under the brake booster). This cable pushes up on the lever when in Reverse (manual transmission) and in Park (automatics). If the lever is not in the all the way up position, you will not be able to turn your ignition key to OFF-LOCK or to ACCESSORY. NOTE, some people disable the back drive cable and secure the column lever in the all the way UP position. Is this backdrive cable operating correctly, or is the lever on the lower end of the column held in the all the way UP position?
If you can confirm the above I will try to contact a Delphi engineer who might be able to help us with this problem. If you want to eMail me or just answer the above on this forum that will be OK.
JIML82@aol.com