Saleen0679 - thanks again for the advice. Replaced the ignition switch this weekend and everything back to normal. Ticked me off that I had to contact Ford 3 times before finally finding out the original recall ignition switch replace HAD been done in 1998 (under the previous owner)...guess the replacement switch was only good for 9 years, because it was obviously in the process of coming apart at the seams. The manual said you only need to remove the steering column housing, but I had to also remove the plastic kick plate and the metal pan under it to get enough access to those tamper proof Torxs. And I would have had to remove more of the dash if my wife hadn't bought me this small hand squeeze ratched device last Christmas. No way I could get a small socket ratchet with the 1/4 inch bit holder and the Torx bit in the small space. That so-called 30 minute job took me about 2.5 hours (but I also had problems getting the steering column housing halves back together). Still, it saved a dreaded visit to the dealer...at least this way I've got the satisfaction of knowing it was done right the first time. Thanks again for the advice.