I just swapped out the steering column in my '91 RS due to the bright lights actuator parts being missing when I bought it. After I swapped out the ignition cylinder I had quite a difficult time getting the intermediate shaft to mate back up with the steering column. I searched and searched but only came up with, file it, sand it, grease it, muscle it. I tried all of those and none of them worked for me until I found an interesting way to apply brute force w/o brute results.

*edit*
First, First off, make sure the battery is disconnected. I did the work with the battery disconnected and all of the steering column wiring outside the column disconnected and the airbag module out of the car. Thank you Pocket for pointing that out, I didn't think about mentioning it sort of figured it went without saying but I guess that's a bad idea.

First off, of course make sure everything is lined up properly and get it started w/ the muscle side of things. Once it's started on its way pull
the plastic protector up off the rubber boot then you can use a soft face hammer along w/ a regular hammer as follows..

Take 1 16oz Soft face hammer..(16oz is what I used)



Rest the hard-plastic side of the soft face hammer against
the joint just below where the steering column and shaft
mate up.




Watch out for break lines and AIR system and all that, and make sure
you're not pinching the rubber boot on the joint.




Then hit the rubber side of the mallet w/ a normal hammer. You've gotta have the angle right. after a few taps you should see it working. If not, try adjusting your angle and checking the alignment of the two parts.




Once I saw the i-shaft sliding onto the steering column I gave it a couple of good whacks and it was on. No problem whatsoever.. after fighting with it
for a few hours ever night. Put the bolt back in, tighten it to torque specs and off you go on your test-drive.

That's about my first contribution to thirdgen.org, I hope someone finds it helpful. Now.. if I can just get the horn to work I can go get my inspection done and get on the road.

 

Hope you disconnected the battery before you went th-whacking at the shaft which incedentally is connected to your airbag

 

There you go Pocket, edited. Thanks for pointing that out, I'd hate for someone to blow the airbag because I left that out. As for th-wacking. I don't recommend a good beating.. it really just took some moderate force taps.