This has to be extremely frustrating Jonesy.
Looks so simple. Wish I could help. It has been 8 years since I assembled mine.
Couple of questions:
1. Is the throttle arm GM?
2. Is the retainer GM?
Going off memory here. I am almost certain, I installed the switch before I installed the arm. Car was apart. Don't know if you have that option.
I am 99% certain I put the retainer in the arm, and then pushed the switch into the retainer. IIRC, it was not really hard to get in.
My thinking is that if your arm and or retainer are aftermarket, they may not be the exact correct size. I rarely find aftermarket repop stuff to be EXACT.
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