Rick:

Thanks for your patience. I have nine of these cars and all the cylinders are the exact same size and none of them will fit over the key head on any of my 27 keys.

Therefore I'm doing something wrong.

The shaft of the cylinder itself will fit over the key head but not the opening of the cylinder (front side hole is smaller).

In thinking through how it came out, it simply won't go back together that way.

Perhaps I have the snap the entire lock and key cylinder out but it went in so difficult that I don't want to take the entire dash out again.

Thanks

Don

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DAILY DRIVERS:
'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

SOLD:
'82 240D 229k (Matt's - Converted-300DT w/ 4 speed