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Got a 2003 ford e450 super duty with a Utilimaster body.
When turning the key to start the engine, sometimes it does not "catch" and it wont start do it again and it will start. Intermittently will go several times with no start to several times turning the key and starting with no issue.
Ignition lock is not loose, turns with a normal amount of strength as any other cylinder lock
Prior related repairs made before I looked at it now.
The steering column has been rebuilt. tube, bushings. ignition switch replaced multiple times. Ignition lock cylinder replaced a few times as well.
When turning the key to start the engine, sometimes it does not "catch" and it wont start do it again and it will start. Intermittently will go several times with no start to several times turning the key and starting with no issue.
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Do you mean the starter engages but the engine doesn't "catch" (start)?
Or do you mean turning the key doesn't engage the starter?
If you mean the starter sometimes wont spin, that happened to me once and it turned out to be loose battery wire connectors. You can try taking them off - check the connectors for security, also clean up the connectors and battery posts. Trace the wires all the way down to the starter and make sure it's all tight, clean, and secure.
Do you mean the starter engages but the engine doesn't "catch" (start)?
Or do you mean turning the key doesn't engage the starter?
turn the key and powers on, no starter activty, most of the time it will engage the starter
tested the wire going from ignition switch to the starter, it wasnt always engaging when key was hitting the start in the switch
threw another ignition switch at it, replaced it a year ago and the issue only came back within the last week. started with no issues.
starter was also replaced last november
this marks the fourth one
replaced in order, first to currently installed: motorcraft - oriellys - autozone (lasted a little over a year.) replaced with another autozone switch.
The number of times new "ignition switch" has supposedly fixed this problem says you're missing something either in the steering column itself of the starter engagment circuits.
The number of times new "ignition switch" has supposedly fixed this problem says you're missing something either in the steering column itself of the starter engagment circuits.
Im calling the ignition switch the ignition switch.
everything seems to be in working order
steering column was rebuilt mechanically
starter has been replaced
cables are not showing sings of corrosion
ignition cylinder has also been replaced
my coworkers are also in agreement that we have replaced it too many times but cant find anything else being the problem, hence why i am here.
You have replaced to "moving" components at both ends of the circuit. There is a good possibility the wire connecting them is broken or making intermitent contact. You said you checked for voltage on this wire when the van was not starting and there was none. Where did you make this measurement? Inspect the wire as it enters the connector at the ignition switch. Check the termination at the other end (starter solenoid?). Maybe there is an visible break in the wire where it is crimped onto the pin in the connector.
You may have to intall some test wires to catch the problem when it happens. You want to test for voltage at the ignition switch connector and the other end of the circuit. If the ignition switch connector is not easily accessible I would install something like these connectors on the wire with a long lead:
Then use a votlmeter or test light to check both ends of the circuit when it won't start.
^^^Along with that suggestion I'd carefully check the under-column mounted sliding contact switch is making consistent contact from the turning of the key cylinder. You don't mention doing any sort of "autopsy" or post-replacement inspection to see if the physical switch itself is the culprit here.
Its entirely possible the rod pushing the sliding contacts is having issues.
