What is ruining the ignition switch?

G

Graham

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I have a 2000 Toyota 4Runner that was converted into a HMMWV type vehicle. When I took it to get inspected, the windshield wipers fuse blew. We started looking for shorts and after wiggling wires for a while, the windshield wipers fuse stopped blowing. Everything seemed to be fine for awhile. Then one day after a rainstorm, the truck would stall when shifted. Once it dried out this problem seemed to go away. Weeks later, after another rainstorm, the windshield wipers fuse blew and the stall when shifting problem started again. This time the ignition switch started acting up, running the starter even after the truck was running and sometimes trying to start the truck without the keys in the ignition. We assumed the ignition switch was bad and replaced it. All the problems seemed to resolve for awhile. Then, they returned. We assumed the ignition switch was bad again and replaced it again. Again all the problems seemed to resolve for awhile. Now, they have returned again. What is ruining the ignition switch? Should we be looking for a bad ground? A shorted wire or componet? Why is this happening usually when there is moisture? Thanks in advance for any help anyone may be able to provide.
 
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Graham said:
This time the ignition switch started acting up, running the starter even after the truck was running and sometimes trying to start the truck without the keys in the ignition. We assumed the ignition switch was bad and replaced it. All the problems seemed to resolve for awhile. Then, they returned. We assumed the ignition switch was bad again and replaced it again. Again all the problems seemed to resolve for awhile. Now, they have returned again. What is ruining the ignition switch? Should we be looking for a bad ground? A shorted wire or componet? Why is this happening usually when there is moisture? Thanks in advance for any help anyone may be able to provide.QUOTE]

It wants to try and start even after you've turned it off and pulled the key out? I had this problem, I had to disconnect the battery to make it stop. I thought it might be the starter, so I pulled it off and had autozone test it. They said it was fine. He told me it might be the starter relay. The guy said to put the stater back in, and pull the stater relay. So that's what we did. Sure enough, connected the battery and it wasnt trying to start itself.

We put the relay back in, and again, it didnt try starting by itself. I got it, and it started right up and turned off without trying to restart.

Hopefully this helps. I know it might seem like a fluke, but (knock on wood) the problem has not returned.
Click to expand...
 
Thanks for your reply lucky'99. We did try replacing the starter relay with no success - couldn't get off that easy! The check engine light came on the last time we had the problem, so we were hoping we could check for a code that could tell us where to start looking. We eventually found the OBDII test interface in a bundle of wires by the gear shifter. It threw a code about the Camshaft Position Sensor. We checked the ground for the sensor and found it was also the ground for the windshield wipers and ignition switch. It was loose, so we cleaned it up and tightened it. We also sealed up the fuse box with some rubber matting. Fingers crossed.

ChildrenOfBodom, here are some pics:

Here it is with 33s I run on it:

http://www.eaghq.com/301409-02.jpg

Here it is with the stock size wheels/tires I had it inspected with:

http://www.eaghq.com/019.JPG

I need to move the rear wheels back a few inches.
 
Graham said:
Thanks for your reply lucky'99. We did try replacing the starter relay with no success - couldn't get off that easy! The check engine light came on the last time we had the problem, so we were hoping we could check for a code that could tell us where to start looking. We eventually found the OBDII test interface in a bundle of wires by the gear shifter. It threw a code about the Camshaft Position Sensor. We checked the ground for the sensor and found it was also the ground for the windshield wipers and ignition switch. It was loose, so we cleaned it up and tightened it. We also sealed up the fuse box with some rubber matting. Fingers crossed.

ChildrenOfBodom, here are some pics:

Here it is with 33s I run on it:

http://www.eaghq.com/301409-02.jpg

Here it is with the stock size wheels/tires I had it inspected with:

http://www.eaghq.com/019.JPG

I need to move the rear wheels back a few inches.
Click to expand...



...ur telling me under all that armor ...there is a 4runner engine and frame body?
 
It is a Kit body so I doubt it weighs all that much. probably similar weight to the original body. FYI my 4Runner is 4800lbs right now and after I add the front bumper, winch and skids I am sure I will be around 5100 or 5200.

OP- I hope that fixing the ground fixes your problems.
 
Yep, it's a 4Runner frame/transmission/engine under there. It's not a kit, but the body is made of aluminum and the hood and doors are fiberglass, so yeah, it's pretty light.

It's suppose to rain here tomorrow, so I guess we'll see if it's fixed then...
 
ok based on the pictures it is not an actual HMMWV body. Happen to be very familiar with them since I have about 50 or 60 I am looking at right now. So it had to a Kit body that you put on your frame. I am glad to see it is aluminum like the actual HMMWV though.
 
Pikeman, are you suggesting I don't know what my vehicle is? It is not an actual HMMWV body. It is not a kit body - it was hand built by a friend of mine.
 
Most people consider a body made to look like another car bolted/ mated to a donor chasis and drive train a "Kit" whether it is a one off body such as yours or a mass produced one. Some people will refer to a one off design a "Special". There is nothing negative in my statement. I think it is a unique idea and your friend did a good job making it judging by the two pictures you posted.
 
I work as a Hands on Maintenance Training contractor for the Military.

Also the problem is most likely the fact that the wiring harness once it enters the body of our 4Runner is not made weather proof. Now that you have done your conversion it has exposed more of the harness to weather conditions it was not intended to encounter.
 
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Well, whatever the issue, it is not resolved. It rained last night and the truck started up fine this morning and shifted into drive just fine. It continued to rain on and off all day today and when I went to go home tonight, the truck started up fine, but stalled when I shifted into drive. Then when I started it up again, the starter continued running after it was already started and it stalled again when shifted into gear...Not sure where to go from here.
 
This is a year old, so has probably been resolved, but I think Pikeman is on the right track. It sounds like somewhere on the wiring the water is creating a circuit, so I'd check the ends of the harness, and that the insulation is continuous on the wiring.

Maybe at a wear point the insulation has worn off a few wires and is creating connections when wet, which would explain the blown fuses and the starter running when it shouldn't.

I'm no expert, but I'm dealing with a different but related issue on my 98 right now.
 
Thanks Giro. Problem is water getting into my fuse box. Still trying to get all the leaks sealed up. I appreciate you taking the time to post!

Graham
 
Off Topic, but if that isn't a kit and it was hand built...Nice Job!!
That is thing is way better than a friend of mine who made a Ferrari out of a Fiero. My only question is why??
 
Thanks Socco. Yep, my friend hand built it. Sorry, I don't know why your friend built a Ferrari out of a Fiero...
 
Graham said:
I have a 2000 Toyota 4Runner... This time the ignition switch started acting up, running the starter even after the truck was running and sometimes trying to start the truck without the keys in the ignition.
Click to expand...

Graham said:
Well, whatever the issue, it is not resolved... when I started it up again, the starter continued running after it was already started and it stalled again when shifted into gear...
Click to expand...

did you ever get this resolved?

the same thing happened to me last week, for the first time in the 15 months I've owned my '96 4Runner SR5... I keep mine in the garage and barely drive it 2-3x a month, so I can't see how I would have any moisture issues...
 
Graham said:
hrt4me: Mine was water leaking into the fuse box.
Click to expand...

thanks for the reply

then my issue must be caused by something else, because I don't have water leaking into my enclosed garage, and I baby my 4Runner and barely drive it 2-3x per month, and especially not in inclement weather
 
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