the key will go all the way to the start position but wont return itself, apparently this is a common problem for the BA/BF/FG and because Ford loves to over complicate things you need to remove the entire steering column to repair/replace it (or so i've heard) is there a technical doco on here that can take me through the process or has someone done it already and knows a short cut?

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pdf that 'may' help.........

You can use an EB-AU assy as a replacement - they don't fail that way for some reason .
The shell doesn't have a keyway like the BA's/early BF's, you can dremel/cut down a self tapper screw screwed into the housing.