Ok, here is the follow-up on the key chime problem. First the short version and then for any still interested a longer one.
It finally really broke, anytime the door was open without the key it dinged. Got the kit. Keying the cylinder was easy; just fiddly (fussy). Replacing it was straight forward. Only problem I had was the electrical contact in the column that interfaces with the switch in the cylinder fell out and had to be zip tied in place.
Long version: The problem got so bad it dinged any time the key was removed and the door was open, so I finally got the cylinder kit. I got a 10 percent discount because I mentioned the Ranger Station and adsm08 to the counter man. Cool.
I decided to try to key the new lock to my key by trial and error before taking it to a locksmith. If was surprisingly easy. I tried to use the diagram in the instructions; but, I found it mostly useless. There are 8 key slots (four on the top and three on the bottom) and five different keys. First thing I discovered is that you have to put the spring in the slot before the pin or you will never get it right. After that is was pretty simple. Just select one of the five keys and go for it. When you think you have the right key for that slot try it to make sure. It took about 20 minutes.
The only problem I had was installing the lock pin assembly (the pin that keeps cylinder in the column). I could not get the ball to stay on the top of the spring and put in pin in. I finally figured out a way to depress the spring and ball, turn the cylinder and then put the lock pin in place.
Now for fixing the truck. The Chilton repair manual says to disconnect both battery cables and that you to have to remove the steering wheel tilt lever to get the lower cover off. But, the lever is a plastic covered metal rod and it in there really tight. There is no way to grab it with anything without screwing it up. But, the lower cover is flexible and you can bend it enough to get to the lock pin release. I used shaft end of an eighth-inch drill bit.
The cylinder comes right out with key in the “run” position. And the new one slides right in. Good to go.
I learned a long time ago working on aircraft to check the fix before putting the panels back. And with battery connected I got Ding, Ding, Ding...... So had to start over.
Cylinder out, and find that the ground contact in the column housing is not where it belongs and is grounding the circuit. Screw around with that and it will not stay in place (the keeper does not lock in). Finally used a cable tie to keep it in place. Put it back together and success.
Conclusion – I really think the key chime has been broke from new. I cannot remember it ever making noise with the key in the cylinder. And, I don’t know if original problem was the cylinder switch or the ground contact. I think I could have fixed it without a new key cylinder after inspecting the way the chime switch is mounted on the cylinder and how the housing contact is installed.
It works now, Ed