Ignition issues - 1991

Took my truck to a shop to get some suspension work done, and now have intermittent start issues. And it's got to the point I need to cross contacts at the solenoid to crank and start it.

Non tilt column. Key turns all the way, but makes no effort to start. Sometimes multiple cycles (key off, key on) will get it to crank. At one time a couple raps on the column with the handle of a screwdriver would get it to crank. Now neither work and the truck sits.

My initial thought was a worn out ignition cylinder. But the more I think about it, it has to be some kind of actuator that makes or tells the computer to crank and fire.

Anyone had this issue or can provide guidance on repair? Is it a common occurrence? Am I on the right track? Anyone have a steering column diagram I could study?

You may need to adjust/replace the ignition switch. (Not the key tumbler)
Take a look around here. http://www.steeringcolumnservices.com/exploded-view-results.php?y=1991&ma=Ford&mo=F250&d=tilt&c=477

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Are you sure the fixed column has a different ignition switch from the tilt? If it is the same switch, it is screwed to the top of the column with two nuts. It is adjustable up and down so you can clock it to the key positions.. There is an actuator rod into it that is pushed by a crappy little pot metal lever under the turn signal switch that is pushed by the ignition cylinder.

I would confirm that the start wire at the solenoid is not getting power with a test light. If it is not getting power, then I would get under the dash and make sure the actuator rod is moving enough. If it is moving enough I would replace the ignition switch. If it isn't pushing enough, I would suspect the pot metal lever is about to die. They break enough that they are available in the help section at the parts store.

Oddly enough, this thread just below yours shows the actuator rod and pot metal lever in the video.
http://www.oilburners.net/forums/showthread.php?78106-Anyone-ever-do-this

Make sure your grounds are good under driverside kick panel, may need to sand off some paint to get a good ground

You may have a broken actuator do-dad. Its a little pot metal piece. Common failure. It is what translates the motion of the key to the ignition switch which is actually down toward the base of the column.

You don't have any sort of computer in these trucks except if you have an E4OD tranny,and that has nothing to do with starting.

Here's your problem.

The linkage between the cylinder and the switch actuator rod is wearing/worn out. Very common .

So what do I tell the Ford parts guy I need? Ignition Switch? Ignition Switch Actuator?


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Well first off you need to see what's wrong with yours.
Otherwise you might as well buy a whole column. Lol

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Which is the problem? Ignition switch is much easier to replace. Replace it and make up a jumper that will go from your batt to your injection pump. Then when the actuator goes out, you can get to the parts store and get a new one from the help! section.

I wouldn't get either part from the ford guys.

fair warning:
when you unplug the connector from the ign switch itself, be gentle and be careful, there's a dorman help replacement pigtail for when it crumbles

Not sure on the 91 but E4OD have a neutral safety switch, on my 94 it was acting up and I had to wiggle shifter from time to time or cycle it in and out of park before it would start.