I had been having a slight hiccup in my truck from time to time (99 F-350, four door, 2wd, 7.3, 6 speed, dually, eight foot bed) as I was driving. It was completely random and started out so subtle that you almost couldn't notice it. I had no idea what the issue was and figured I'd find out at some point.

Well about four days ago I found out the problem. It was the starter switch. I was traveling down the road with no issues when all of a sudden the truck died. This had happened before on rare occasions when one of the big main fuses had blown, but on those occasions everything electrical died as well. This time my radio and accessories still worked as well as the lights, as I had to use my four ways. I went to switch the ignition switch off and it wouldn't move in either direction, it was stuck in the "on" position. I assumed it had something to do with the lock cylinder so I removed it. That wasn't the problem. I began ripping into the column to see what I could see and eventually I tracked the issue down to the starter switch.

As many of you are aware, the starter switch is under the dashboard kind of near your shins. I was not aware of that or else I would have just replaced it without having messed with anything on the column up near the steering wheel. I got a new switch and replaced it and I re-assembled the column, but I have a problem still which is at this point beginning to drive me mad.

I don't post much on here because I'm a fairly capable mechanic and usually end up figuring things out one way or another. This problem I seem to be having trouble with. It seems like I have a problem with the "timing" of the ignition switch gear and the rack it rides on, assuming the aftermarket switch isn't to blame. The switch works the way it should in accessory, off, and on, but it will not start the truck using the key. If I pull the starter switch off the column, put the key to on, and step on the clutch, then MANUALLY operate the switch outside of the column, the starter engages. If I install the switch in the column, it's as if the rack doesn't have enough travel or the gear is stopping the travel of the rack, or something, I don't know. It will not engage the start position on the starter switch when everything is put back together. I have tried the ignition gear in multiple different positions on the rack and had no luck at all.

My questions are, is there a way to "time" this gear or something? I can see the mark on the column where to install the starter switch itself, but I see no marks on the gear or the rack.

Is it possible that the new aftermarket switch is to blame? I'm coming up on day three of working on this and I have places I need to drive and this is getting very aggravating. Any help would be greatly appreciated.

 

As I type this now, I tend to think the replacement aftermarket switch just might be to blame. The hole in the rod that the switch engages is in the right place, everything appears to be working and the rod appears to be traveling the distance it should be. It does work when off the column, but it stuttered a couple of times just now trying to start it before it would engage the starter fully. I might try to find a different switch.

 

Problem solved! BWD switch brand new from Advance Auto Parts was no good. Napa brand switch fixed the issue.