I need to know how the contacts work in the ignition switch. I'm having an issue where sometimes the car will start fine, but others it will click once and do nothing. Sometimes turning the key again works, others not for 10-20+ times or so.

However, I discovered that sometimes if you pull the wheel all the way to it's lowest position it will start.

I THOUGHT I found the issue when I found that if, as I turned the key to start, that if I reached down and grabbed the actuator rod and pulled it towards the steering wheel as the key was also pulling it towards the wheel, the car would always start. I just replaced the switch with a new one, but I'm still having the click once problem. Starts fine sometimes, lots of click once another.

What I need to know is, with the contacts in the switch, does one contact cause the solenoid to engage(which is the click I'm hearing as it DOES extend out when it clicks) and another contact just a tad further up or down makes the starter motor turn. If that's the case, then it's likely that I need to adjust the switch up or down on the column which should cause the contacts to reach the contact point that tells the starter motor to turn better than it is now.

I took a picture of the 2 sections of the old original switch that I opened up. The contacts bars in the black piece and not in their original spots and one is missing that I dropped, so ignore that. Judging by what I think happens, is the contact bar moving past the "tell the starter to turn on" point or is it not reaching it? That should tell me if I need to adjust the switch a bit towards the wheel or down towards the firewall. Picture is cropped but left large to get a good view of the contacts.

For what it's worth, the starter has been replaced, all cable contacts scoured clean, new alternator and battery.

 

Does anyone have any information or suggestions on this?

 

The start contacts in the switch energize the relay which engegizes the solenoid. Once the solenoid is energized it moves an arm to kickout the startes drive which closes a contact disk in the startes to power the motor to spin the drive.

The last time I had a start problem where you had to pull the wheel full down to start I found the rod from the key tumbler to the start switch was bent. I have also found the rack for the tumbler had slipped or broken. With the wheel in another position than down it wouldn't actuate the start switch far enough for good contact. That was caused by the tilt mechanism torx bolts being loose.

 

I suppose my first stop should be adjusting the switch a tad by moving it down towards the firewall. Since the rod pulls the switch towards the wheel, theoretically, if the switch isn't making proper contact then adjusting it like that should make the rod pull the switch just a millimeter or so closer to the wheel.