Gen II steering column snafu

[olddavid]

My column became so loose it was dangerous. I found a low mile one that was tight and even had the right color. Here's where the problem starts. On my car there is a standard bolt that tightens the u-joint around the rod from the steering gear. On the replacement, it had a 1/4 inch star nut that proceeded to round out as soon as I put pressure to it. So, I took my angle grinder and ground the edges off so I could remove the connector and install the new column. Now, the movement of the steering rod is compromised. Do I now need to go further down the column and source a new/used one to go to my steering wheel? Have you ever heard of this happening? I now realize I should have bit the bullet and just changed the potentiometer. Any ideas?

 

[olddavid]

I gave up too soon. All went well after a few hints from someone who has already done one. Just remember that both ends of the steering shaft will slowly extend until they fit.