Okay I've got it working. Couldn't budge the Allen screw so I had to drill it out. Turns out you don't have to touch it if the unit is not attached to the vehicle. There is a pin that holds the handle onto the shaft and once the handle is off you can access the guts of it.
The problem was the tongue was sticking out about 25mm and therefore wouldn't retract far enough to click into place.
Once I could access the guts and remove the red plate I put the handle back on and turned it far enough for it to come all the way back into the housing and click into its normal position. The tongue now protrudes about 10-15mm and the unit just pushes into the housing easily.Not sure whether I would trust it towing the van given that I am the one that pulled it apart and this ball bearing appeared magically out of nowhere. Still don't know where it is supposed to go.
Oh well if you haven;t got any parts left over then you aren't trying hard enough.
Still looking at the replacement.
Mike
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