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  #13  
Old 07-26-2013, 07:19 AM
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Re: 2003 4.7 starting issue

Making progress! Retested terminal 87 to starter and it was good. So I reconnected it and tested 12V to 87 and the starter cranked. Must have just been a bad connection at the solenoid when starter was changed.

I then took dash out around steering column to get to C1 connector on back of ignition switch. I made a jumper wire and connected 1 and 2 of the C1 connector and the engine started. With that test done I put the C1 connector back in, and verified I could start still with 12V to 87 with ignition in the run position. All was good. So it definitely looks to be the ignition switch. I need to get some tamper proof torx bits to get it off.

During all this testing I ran into another problem, that I'm not sure is because of the bad ignition switch. Within the last few days the battery went dead, so I've been having to jump it to do my testing. I noticed after testing yesterday the time on the radio was still on after key was turned off for about 1 hour. Could the bad switch be leaving acc devices on and draining the battery?

Also last night once I was done testing, I let it run for about 20 minutes to get the battery charged. I figured why not take it for a spin. Didn't even make it out of the driveway. Once I put it in drive and tried to accelerate, it died. I started it again with 12V to 87, and pulled it in the garage. As soon as I let off accelerator, died again. Seems that after start it idles fine, but if you rev engine and take foot of accelerator it idles way down and stales.
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  #14  
Old 07-26-2013, 10:54 AM
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Re: 2003 4.7 starting issue

Sometimes with a worn key cylinder, you can pull out the key in ACC position, this is not good. When you know this problem, you could verify it to be in off and not ACC before taking out the key, but better would be a new key cylinder.
Did you charge the battery completely before driving? I would check the battery voltage with engine off and then with engine running. In off it should be 12.7 V for a fully charged battery, when its 12.2 its almost completely discharged. With engine running it should go to 13.5-14 V.
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  #15  
Old 07-26-2013, 11:28 AM
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Re: 2003 4.7 starting issue

I'm pretty sure the key didn't come out before going to off, but I could be wrong, I'll have to check that out.

I didn't charge the battery all the way before driving. I've always been able to run off alternator when battery was dead, before jumping, and not had any issues, like stalling out. Once ignition switch is replaced, we'll see if those two issues go away.
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  #16  
Old 07-26-2013, 08:05 PM
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Re: 2003 4.7 starting issue

Yes, best to change the ignition switch first and then see what happens. If you have a charger, i would start with a fully charged battery and then see if all is ok.
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  #17  
Old 07-27-2013, 02:27 PM
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Re: 2003 4.7 starting issue

Well, got ignition switch replaced and it seemed much better until this morning. I turned the key and it was like it wasn't hooked to anything. I took the cylinder back out, and removed the ignition switch. And there is was, the end of the rod that connects cylinder to ignition switch was broke, about 1/2 inch off the end. That would explain why it wouldn't start and why it was draining the battery with the ignition off and key removed.

So it looks like it's contained in a small box held on by 2 torx screws, has cable coming out of the back. Any idea what that box is called? Is that box or rod something that can be replaced?
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Old 07-27-2013, 04:49 PM
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Re: 2003 4.7 starting issue

Is the rod not a part of the key cylinder? No idea which box with wires you are talking about.
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  #19  
Old 07-27-2013, 04:59 PM
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Re: 2003 4.7 starting issue

Looking into the manual i see that the SKIM is placed just above the ignition switch, but that one has nothing to do (mechanically at least) with the key cylinder or ignition switch.
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  #20  
Old 07-29-2013, 07:41 AM
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Re: 2003 4.7 starting issue

Ignition Switch Actuator Pin. That is the name.
Here is what it looks like new.

I'll post a picture of the broken one when I get home. Basically the last 1/2" of the rod (right side of picture) was broken off. That is that part that goes into the ignition switch. Thanks for all your help Frank, couldn't have gotten it fixed without you.
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File Type: jpg 10050528_dor_924704_alt2_detl.jpg (4.8 KB, 13 views)
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  #21  
Old 07-29-2013, 04:46 PM
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Re: 2003 4.7 starting issue

Is this a part of the key cylinder?
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  #22  
Old 08-05-2013, 09:40 AM
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Re: 2003 4.7 starting issue

Yes, that is the part that sits between the Cylinder and the ignition switch. Here is a picture of my part to compare to the new one I posted before. As you can see the rod that goes through the middle, that connects the D shaped end of the ignition cylinder to the smaller D shaped connector on the ignition switch is broken right off.
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  #23  
Old 08-05-2013, 11:56 AM
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Re: 2003 4.7 starting issue

Never heard of this part broken. Good that its fixed.
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