No crank no start after ignition key cylinder replacement?

Tiny
WHATWARRANTY
  • MEMBER
  • 2001 FORD MUSTANG
  • 4.6L
  • V8
  • 2WD
  • MANUAL
  • 205,000 MILES
I drilled out the old ignition switch and replaced it with a new switch from O'Reilly's and ordered one from car-part. Com to have a backup in case something went wrong. I removed the steering column in order to do this on a bench. I am confident that I plugged all the connectors back up when I put the column back in the vehicle.

Using Forscan was able to program two new keys to PATS and have no codes related, theft light turns off after 3 seconds of key in run position so I'm confident this is not a PATS issue.

Key will turn on dash, radio, and I can hear fuel pump priming.

When I attempt to start everything normal happens except no crank. I can hear a click from the steering column.

When I jump the relay under the hood the vehicle will start and run with the key in the run position and will shut off when I turn the key to the 0 position.

Checked with a test light power from pink and white wire at the loom on the steering column that goes into a white I'm guessing junction box (?) And have no power in wire

When I check the number 6 fuse (15 amp) which is the starter relay mini fuse under the dash I have no power when I turn the key to position 3 or crank/start on either side of the fuse, nor any power with fuse removed and checking directly at both sides of the slot.

I also have no power on either side of my clutch safety switch.

When I removed my old cylinder then I guess you'd call it a prong (?) At the end of the cylinder was broken off in what seems like a gear. I had to remove a metal retaining bracket and the gear using needle nose pliers to remove the broken off piece. I then put the gear back in the only way it seemed to fit and still lined up with the ignition cylinder. I then used a large flathead screwdriver to check movement and it seemed okay. Put metal retainer back on, green plastic retainer back on and was able to slide my new ignition cylinder into the housing. Now I'm stuck with a no crank situation.
Sunday, July 9th, 2023 AT 8:31 PM

2 Replies

Tiny
WHATWARRANTY
  • MEMBER
  • 2 POSTS
Holy Mary and Joseph, I figured it out. It's almost too embarrassing to admit but in keeping with this site's protocol of putting the answer for all to see and most likely laugh like hyenas at, the problem was a fuse. I had been probing the wrong fuse the entire time. I was probing number 7 fuse apparently and not number 6 fuse and that fuse had a hairline crack in it this whole time. I swapped it with a known good fuse and much to my relief and lifelong embarrassment it fired right up, and I swear from the exhaust I heard the car chuckling at me. So yeah, to state the obvious check all fuses and then double check all fuses and do not rely on random websites to tell you which fuse is which number get the correct answer from your manufacturer.
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Monday, July 10th, 2023 AT 9:44 AM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,656 POSTS
Yep, it happens good job hanging in there to figure the problem out. Thanks for letting us know, we are here to help, please use 2CarPros anytime.
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Monday, July 10th, 2023 AT 12:23 PM

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