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And the winner is Thom4782! Thanks for your guidance.
I took off the airbag a couple of days ago and both horn wires looked good. Today I decided to completely disassemble the entire steering column, and after what has to be the weirdest failure I've ever seen it turns out the conductors of a horn wire were broken, but enough wire insulation remained to make it look connected.
Why the honking worked with ignition off (and wire broken), but not ignition on completely escapes me particularly as the the ignition wiring was disconnected, but there it is.
The seeming correlation between removing the vent and the horn working had to be pure chance.
The only electrical connection in the ignition assembly was the two little wires just above the ignition tumbler.
In any event Thom4782 is right, if the horn honks with ignition off but not on, even if the wires look good, likely they aint!
Thanks all.
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2003 S manual
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