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Old 07-06-2020, 06:15 PM   #1
gammynet
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Changed key lock cylinder, ignition switch more problems

Van would start but not shut off, had to pull ignition wire clip to turn off and because of daylights, pull positive cable on battery. Easily done but annoying so....
Changed out key cylinder lock, nada
Changed out ignition switch and now, besides not starting at all, day lights not turning on, wipers not working.
(I have a actuator rod but am loathe to tear anything more apart until I know what I've done to the ol' girl)

Dome light, chime, headlights, tail lights all work.

I'm at a loss. This is beyond me.
Any ideas will be greatly appreciated.
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Old 08-02-2020, 11:39 PM   #2
wiswind
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Re: Changed key lock cylinder, ignition switch more problems

Can you post the year of your windstar?
The electrical layout varies from year to year.
Sorry that this room is not so active anymore.....not so many windstars out there now.

When you say "not starting" does it turn over?
If it turns over, but does not start.....you will need to see if it is lacking fuel or lacking spark.

Fuel pump and fuel pump relay.

If it is not turning over.....several off the wall things that have happened....
Neutral Safety switch....also called Transmission Range sensor......is known to fail. Try shifting from park to neutral and see if it turns over.

Brake switch.....keeps car from starting unless your foot is on the brake pedal.
I had a wire frey and fall off of mine......causing no start.
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Links to my pictures, intended as an aid, not a replacement for, a good repair manual.
1996 3.8L Windstar
http://www.flickr.com/photos/4157486...092975/detail/
2003 Toyota Sienna pictures (not much there yet)
http://www.flickr.com/photos/4157486...781661/detail/
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Old 08-03-2020, 11:34 AM   #3
gammynet
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Re: Changed key lock cylinder, ignition switch more problems

I found my much need patience and went back out to try Again. The ignition switch was that problem, took out and reinstalled. All is well in the world again. Well, it runs. Still won't shut off. Sooooo, change actuator rod, swap steering column or find The wire in ignition cluster and put in toggle. Have not decided on course of action yet.
lol Rain and 60 mph wind keeping me indoors for now.
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Old 08-05-2020, 04:19 PM   #4
12Ounce
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Re: Changed key lock cylinder, ignition switch more problems

As you know, the ignition switch is a plastic box affair down the steering column several inches, actuated by a linkage hooked up to key tumbler. i have had to replaced this switch box on my 99 ... little problem. But if you try to replace key tumbler and keys, it's another ball game altogether.

To paraphrase from my Windstar shop manual;

..As the new vehicle comes down the assembly line and the battery is connected for the first time; an operator installs a first key and turns on system, withdraws this key and does same with second key, withdraws this second key and reinserts the first key, turning on system. At this point, the PAT device around the tumbler, the chipped key, and the PCM have become "married" by the assignment of a random set of 8 numbers derived from a digital "roulette wheel". This is all managed by the instrument panel. The operator again inserts the second key and it gets its assigned number. Six more keys can be added to the key set using procedure outlined in owners manual.

If the key set, the PAT, or the PCM (perhaps the instrument panel also) are ever to be replaced, special equipment at dealership will have to be involved. Or so i believe I hope i got most/some of this correct.
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Old 08-06-2020, 09:46 AM   #5
gammynet
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Re: Changed key lock cylinder, ignition switch more problems

No marriage involved. Good ol Ford technology, one key to rule them all. I actually have four, lol. '96 (Fall of 95 build).
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