Intermittent key turn/starting issue

[jlo24141]

Hey all,

2005 TJ X, automatic, 4.0. I have an issue where sometimes I can't turn my key all the way to start/run, and sometimes it doesn't start anyway. It seems like the mechanical issue of not being able to turn the key all the way through start is causing start issues because of the weak electrical connection that's being made. Here's what I've done about it so far:

- Happens in park and neutral
- Wheel is not locked
- Battery is good
- Big 7 wires installed over a year ago
- New ignition relay
- New starter
- New ignition cylinder (happened w/ old one too)
- New ignition switch actuator (x2)
- New ignition switch (x2)
- Cylinder + actuator + switch rotate freely when not installed
- Steering lock spring and the tiny metal piece is installed correctly, being that the spring goes from the post to the circular cutout

1) So what's left for troubleshooting?
2) Why would the cylinder be jamming up intermittently, causing causing no-starts and slow struggle starts?
3) Should I just disengage the steering lock altogether, or is there something to look at there?
4) How do you disengage the steering lock safely anyway?

 

[macleanflood]

You replaced the actuator pin too?

-Mac

 

[jlo24141]

You replaced the actuator pin too?

-Mac

Yeah, the whole actuator assembly

 

[macleanflood]

How worn is your key?

-Mac

 

[jlo24141]

How worn is your key?

-Mac

Ah, I should have added that it happens with a fresh cut spare as well as my original key

 

[5TTTj]

Did you set the actuator pin on the correct side of little cam within the unit ? If I recall there is certain place it needs to be set during assembly. Maybe Im wrong. ???

 

[jlo24141]

Did you set the actuator pin on the correct side of little cam within the unit ? If I recall there is certain place it needs to be set during assembly. Maybe Im wrong. ???

Yes, you're right that there is a certain side that the brass rides on to make the spring work. I have it on the correct side (I tried both sides to be sure and one side wouldn't let it turn at all).