Struggling to remove ignition switch

[Nicola&Tony]

Van won't start (complete silence on final turn of the key) so I'm working my way through a list of possible causes after searching previous threads on here. So now I'm trying to replace the plastic ignition switch by following Red Westie's instructions in this thread:
https://club8090.co.uk/forum/viewtopic.p ... h#p7612068" onclick="window.open(this.href);return false;

Remove steering wheel being careful not to disturb it's straight ahead position.
Remove plastic column housing
remove switch gear (3 screws)
knock around the shear head of the housing clamp (underneath) you can put an ordinary 8mm bolt back (this shear bolt is supposed to offer a little security that's all)
Put the key in the lock first position
Pull off the lock mechanism
Pull off switch plug
Take out the ignition switch retaining screw
Swap over with new switch
rebuild
Done

I'm about 90% done, but having removed the bolt from the housing clamp and put the key in the first position, when I try to pull on the lock mechanism nothing happens, it just won't budge.

It looks like there's a black plastic tube near the end of the steering column / spindle that could be stopping the thing from moving, do I need to remove this somehow?

Would really appreciate some info about what the problem is and how to solve it. I'll take a photo if it'll help?

Cheers

Tony

[Mocki]

tony, have you got a replacement switch?
if you have i would just pull the plug off and connect the replacement, see if it really is that.

normally they dont just fail.... they fail intermittently over a short period of time....


im not sure what you mean by plastic tube?

martins instructions seem correct to my somewhat foggy memory..... although like i say you dont need to remove it to proove it!

[Nicola&Tony]

Thanks very much Steve, I didn't realise it could be tested like that! I've got a new switch ready to go on so I've been out and plugged it in and put a screwdriver in the opposite end to turn it. When I do that I can hear a click coming from somewhere in the van (not the lpg click though!) and I don't get that click with the old ignition switch, but still no other sounds (e.g. trying to turn over), so I guess it's not the switch at fault then?


So I guess I'm onto the starter bush now then (only changed it 3 years ago!) as I've already:

> fitted a new battery and cleaned its terminals
> replaced the spade connector on signal wire for starter motor
> replaced the earth strap from gearbox nose with a new strap (and cleaned-up all the areas that the strap comes into contact with)
> cleaned-up the battery earth strap and its contact areas
> starter motor was checked by a local auto-electrician in August (and he said it was working fine) when we were having the same symptoms. It's a new starter motor from gsf that I fitted in 2008. I fixed the problem in August this year by cleaning up the earths.

If changing the starter bush doesn't work I'll maybe have to think about replacing the entire signal wire?

Cheers

Tony

[Mocki]

go about it logically Tony.

run a temp peice of wire from the known good switch, to the spade connection on the starter. under, near or around the van, just to eliminate the signal wire.... you dont need to disconnect the signal wire, just run another at the same time....

[Nicola&Tony]

. . . from the known good switch . . .

Sorry for being dim but is that the new switch or the old one that's still in place?!

Cheers

[Mocki]

well i would use the new one... proove no difference or fault, then once you know what caused it, swap back to whats not at fault......

[CovKid]

If connections to starter are sound, do check the small earth between starter solenoid and starter body as these can be prone to rotting away. Otherwise starter could simply have reached end of its life. You could remove it and test direct on battery to make sure?

[Nicola&Tony]

well i would use the new one... proove no difference or fault, then once you know what caused it, swap back to whats not at fault......

Big Tam is gonna pop round tomorrow to help with this 'cos I'm starting to feel out of my depth now!

Tony

[Nicola&Tony]

Otherwise starter could simply have reached end of its life. You could remove it and test direct on battery to make sure?

The strap looks ok and the starter is only 3 years old and was bench tested by an auto-electrician in August this year. Could it really have reached the end of its life already?! I can get it tested again on Wed if it's not running by then.

Tony

[Mocki]

do your self and Tam a favour then Tony, put the starter battery on charge over tonight, so whatever you test you are doing with a fully charged battery tomorrow!!

[Nicola&Tony]

Yeah, done that, cheers Steve

Tony

[Nicola&Tony]

Eeh well, it's amazing what half an hour and a bloke who knows what he's doing with a meter can achieve! Signal wire was tested and was fine. Ignition switch was tested and was fine. The bliddy starter motor was stuck and I hadn't clouted it hard enough with the hammer!

Cheers Tam, it's very much appreciated!

Many thanks also to Mocki and CovKid for their input yesterday

Tony

[BigTam]

No bother mate, was a pleasure, always been good with a big hammer