Jose A,

If you're hearing a "click" or "clunk" when you turn the key to start this may be the starter relay activating to send power to the starter solenoid which then activates to send high power to the starter. My '92 had a problem with the starter solenoid copper contacts having worn down to almost nothing. Removed starter and replaced these copper contacts (approx. $4.00) alls well and starts everytime.

Just my 2cents. LOL

Ron

 

Ron:

I did some checking today; It doesn't look like the Starter Relay
or the Starter itself is the problem; Connections are tight and clean at the Battery/Starter/Relay; I think it's the Switch (where
the Key is inserted to start the engine). It is way too loose,
I can turn the chromed part to the front and to the rear without the key in it. could those Pins cause that abnormal motion ?

do you have a Part Number ? Will Auto Zone or similar parts places have those pins ? I won't bother with the Ford Dealer because they'll want to sell me the entire Steering Column which contains the Switch !! I'm sure you've all been-there-done-that.

thanks,
Jose

 

Jose A,

The copper contacts I was referring to are an internal part of the starter solenoid, not the ignition switch.

From your description, you can move the ignition switch forward and back without the key. This should not happen. It sounds like the ignition lock cylinder may be spinning in the housing and not properly engaging with the ignition switch all the time. In other words, your problem may not be with the ignition switch, but with the ignition lock cylinder. The ignition lock cylinder is where you insert the key. The ignition switch is activated by turning the ignition lock cylinder which turns the ignition lock drive gear via a shaft and activates the switch accordingly. If the shaft from the lock cylinder to the lock drive gear is broken, then it may not fully turn the drive gear. If the lock cylinder is rotating in the housing without the key inserted, then the lock cylinder is probably broken internally or the lock retaining pin is broken or disengaged.

To check the retaining pin, try to gently pull the locking cylinder out of the housing. Don't pull it all the way out, just see if it moves. If it does move outward, then the retaining pin is not engaged and may be broken.

Do you have a repair manual? If not, here is a short description of how to remove the lock cylinder in a 92 Aerostar, but you should get a manual to see the pictures and for more detailed instructions. (Page 8-22 Chilton's 86-97 Repair Manual) Note: there are different directions for 86-91 vehicles, for once the 92-97 models have an easier go of it.

1) Disconnect the battery.
2) Look under the steering wheel directly below the ignition lock cylinder. You will see three wholes in the trim. Two are screws holding the trim on and the third (the middle hole) is an access hole to the cylinder lock retaining pin.
3) Turn the ignition to the run position.
4) Remove the lock cylinder by pushing the retaining pin in with a drift or punch inserted through the access hole and pulling the cylinder out of its bore.
5) Once you have removed the lock cylinder, inside the bore is a snap ring, a washer and the ignition lock drive gear. Remove the snap ring, washer and drive gear. Note the position of the drive gear so it can be replaced the same way. Clean all components of any metal shavings. Check them for wear.

If your lock cylinder is that loose, then you should probably replace it. Check with AutoZone or O'Reilly's Auto Parts. They should have a replacement lock cylinder. They did for my old Pontiac. Otherwise you may have to check out the yards. A replacement from the dealer will in all likelihood be priced out of this world.

Let me know what you find. LOL

Ron