1999 expedition, 5.4

Turned the key too hard and it's stuck in the "on" position even with the key removed. have to start it with ignition switch and disconnect the battery every time I park so it doesn't drain.

I Think it's something internal with the ignition lock cylinder but I can't afford to change it out.

Has anyone else done this to themselves .. Is there another way to fix it without buying a new one. Even if I had the money to replace it, I Really don't wanna carry two sets of keys... LOL. Oops 😬

 

Not sure exactly how the release tab works with expedition, other ford in general, you insert something like allen wrench into the hole, pick the biggest (in diameter) wrench that's slightly smaller than the hole, while pulling the lock cylinder out.
Once you get it out, use dry lube to lubricate it, you can't use any wd40 or white lithium grease, it must be dry lube.

 

Is there a way to adjust it once it's removed? I will try lubing it but I think something snapped inside the cylinder, or something. Doesn't matter which way you turn the key, it registers as "on" - won't crank or turn "off"

 

The ignition lock cylinder, when turning, will only move the **** (as shown above) on the ignition switch. If something is stuck more than likely it's the ignition switch, not the lock cylinder. The ignition switch itself is under $20, you don't need to buy motorcraft.
When the ignition switch is removed, move the **** left and right by hand there is a spring return from start back to run position and it's pretty tight, 2 fingers to move it. If the spring is too loose or stuck just disassemble it and try to fix it or just buy a new one. Your lock cylinder should be fine, no worry about the need to replace new keys.

 

I've been driving it by manually cranking it with the ignition switch, the ignition cylinder turns and the key comes out, but it is stuck in the "on" position even when the key is removed. It felt like something snapped inside the lock cylinder, I'm trying to find a way to repair the cylinder without replacing it. The ignition switch is working fine. Otherwise, I guess I'm lucky that it is stuck "on" instead of "off" - because I can still drive the damn thing lol.

 

You know you can start it directly at the ignition switch, so the problem is probably broken or missing spring or pin inside the lock cylinder.
What you can try is using air compressor and dry lube. Use air compressor to blow the dirt or residue out, whether or not they exist, for the peace of mind, then use dry lube.

If you just don't want to get new set of keys maybe you should get It's a repair kit, get it on Amazon so it's free return, go there and read some reviews then you get an idea, it can take a few hours to get it done, if at all successfully.
Or just buy a new switch if yours is not using transponder key then no programming needed. I'm sure you can replace it in 3 minutes by now. Then just set up a keyless entry system and call it done, just replace your old key with the new one.