As far as I can remember, the factory ignition switch (I guess you call it) has always be unreliable.

Turn the key and you never knew what you were gonna get. Sometimes the motor would start, other times you better hope your parked on a hill :/

Since I couldn't count on the factory ignition switch, I ran a momentary push button from the battery to the starter and mounted it under the dash. The push button ALWAYS works.

Now it seems using a key will not start it at all anymore from the past few times I have tried. I'd like a little help finding out what the problem could be, and what my most effective chance of fixing it would be.

Should I suspect the ignition switch itself? Can a new switch be popped in rather easily? Could I disassemble it and my current one to use parts to allow the use of the factory key to keep it inline with the door locks?

Would you suspect something else? Wiring?

Only thing different ignition wise is a msd dis-2 box.

Any ideas, suggestions, etc. ? Thanks.

Try replacing the ASD relay.

the ASD controls the power circuit to the pump, injectors, and coil pack...a way to check if it works is when you turn the ignition switch to KOEO (key on engine off) you should see power at those components, after a few seconds the computer switches the ASD off though, so you must be quick. a simpler method is, if you hear the fuel pump whine when it primes on KOEO...the ASD works. the asd doesnt directly affect the control side of the starter circuit.

it could be a wiring problem though yea, thats what id go for anyway. the starter itself is controlled off the S terminal control side (small wire on the starter) if somehow the wire or the connection at the ignition switch has some unwanted resistance or a short in it, the starter cant turn because the B+ terminal can never jump to the M terminal.

thats why when you manually jump the S terminal to the B+ on the starter, it works everytime. you removed the contreol circuit side. isolating the problem.

could be the ignition switch, id check for power at the S terminal when cranking....no power, suspect the ignition switch and or wiring. voltage drop tests will pinpoint the problem.

as far as replacing the actual ignition switch, its not so bad....but i dont think you'll be able to use the same key which sucks. i use a 95 eclipse key for my doors, and a 96 talon key for my ignition and trunk because my car was broken into and the locks fucked up...i just got used to it. our ignition switch is really very very simple, and has the steering wheel lock built in.

wiring diagrams, and a DVOM, are going to be your best friend in this case

edited because i cant spell.

Yeah, when I turn the key to the on position, I hear the loud ass pump from hahn :-) But when turning it further to turn the motor over, I get nothing... no sounds, no nothing...

I will get out the FSM and take a look at the ignition system... Yippie... Ugh.


Edit: So it sounds like I can rule out the ASD relay?

On my 96 and 97 the ASD does not affect the fuel pump.

Use a voltmeter and probe the starter wire under the dash off the ignition switch. When you turn the key you should have 12+. if you dont, check that 12+ is going to the switch. If you have 12+ at the switch but nothing on the starter wire, your switch is bad.

Start with the source of power that turned the solinoid over and work downstream. Dont hunt around at random parts you suspect bad.

Thanks for the suggestion.

I am looking over the FSM now...

Gonna take a look at her tomorrow morning and start looking into it.

Just get a volt meter and a starter circuit schematic. Find a place near the middle of the circuit and test for voltage. If you have the voltage, you know the problem is in the second half of the circuit. If you dont have the voltage, the problem lies before the test point. Just keep testing for voltage until you find where the voltage appears on one side and not the other. Atleast that is how I was taught.

I have mine wired with a button for the same reason, and the funny thing? I've checked for 12v+ on the solinoid wire when the key is turned to crank, and it's got power.. but it doesn't engage the starter. The button works every time.

I've never bothered to try to fix it beyond adding a pushbutton :shrug

Originally posted by DarkOne
I have mine wired with a button for the same reason, and the funny thing? I've checked for 12v+ on the solinoid wire when the key is turned to crank, and it's got power.. but it doesn't engage the starter. The button works every time. I've never bothered to try to fix it beyond adding a pushbutton :shrug

Dino, you mean you checked for 12+ at the S terminal on the starter while trying to crank...saw voltage...and it didnt turn? :wary

seems crazy to me. S terminals control side circuit controls whether or not B+ and M will ever even touch...

your button is hooked up from S to B+, yes?

Well, I didnt look into it too deeply...

I ended up checking the ignition switch's starter wire for power when turning the key to 'start' and was seeing 12v.

Rather than trace it out, since I already had a push button ran under the dash, I just unhooked it and teed it into the starter wire on the ignition switch.... bypassing all of the factory wiring.

Seems to work just fine. Started all day that day which is uncommon.

The only small 'issue' is that I bypassed the clutch pedal switch, so you can start the motor without holding down the clutch pedal.

Originally posted by turbo8u
Dino, you mean you checked for 12+ at the S terminal on the starter while trying to crank...saw voltage...and it didnt turn? :wary seems crazy to me. S terminals control side circuit controls whether or not B+ and M will ever even touch... your button is hooked up from S to B+, yes?

Say what? The button runs from the battery to the starter solinoid wire. It completely bypasses the ignition switch.

I can see 12v+ on the start solinoid wire with the ignition switch in the crank position, but the starter does not engage. Bump the button, and it does. I don't care to fix it beyond hitting the button, so i've never bothered to investigate why it happens.

Originally posted by turbo8u

Originally posted by DarkOne I have mine wired with a button for the same reason, and the funny thing? I've checked for 12v+ on the solinoid wire when the key is turned to crank, and it's got power.. but it doesn't engage the starter. The button works every time. I've never bothered to try to fix it beyond adding a pushbutton :shrug

Dino, you mean you checked for 12+ at the S terminal on the starter while trying to crank...saw voltage...and it didnt turn? :wary seems crazy to me. S terminals control side circuit controls whether or not B+ and M will ever even touch... your button is hooked up from S to B+, yes?

Very common issue with older ford explorers and many other domestics. Its typically corrosion inside the jacketing of the wire or at harness connections.

Terry

The wire isn't connected at the terminal. my solinoid harness had a spade connector about 8" off the starter. My wire splices in at that spade.