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Re: 1998 Ford Windstar - Turn key and engine won't turn...
Obviously a short is what you're dealing with. If you can take the cover that goes over the steering column so you can see the wires you will probably be able find where the short is occuring. Look for sharp metal around the wires or points where the insulation has been wore off.
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A metal activator rod generally moves back and forth along the steering column from the key lock to the ignition switch (generally mounted on the steering column. If the rod had been dislodged or the ignition switch had shifted position during your pervious efforts, turning the key will not allow the voltage to get to the starter.
Be prepare to be very uncomfortable twisted around under the dash and steering column. :(
Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder.
Twist the tilt wheel handle and shank (3F609) and remove.
NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover.
Remove the upper and lower steering column shrouds.
Remove the three screws.
Remove the lower steering column shroud.
Remove the upper steering column shroud.
Remove the multi function switch.
Remove the two screws.
Disconnect the electrical connectors.
Remove the multi function switch.
NOTE: When the battery (10655) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure.
Fuse panel is located behind the instrument panel to the left of the steering column. There is also a fuse panel located on the left side of the engine compartment. Fuses #25 and #27 on the interior fuse panel are both associated with the turn signals.
I hope this helps you!
When i worked for a Ford dealership in 1989 there were many issues with ignition switch contacts. They tended to work loose, make poor contact and burn wires. A new switch, connectors and wires will be needed to repair.
Step 1 Disconnect the negative battery cable from the terminal on the battery. Remove the upper and lower steering column covers by unscrewing or unclipping them. Step 2 Remove the steering wheel by lifting off the center cover, disconnecting the horn wire and removing the retaining nut and washer. Make a mark on the steering wheel spline and the wheel itself so you can line it back up precisely. Pull the steering wheel straight back to remove from the shaft. Step3 Take off windshield wiper and turn signal switches by pulling them off as you did the steering wheel and disconnect the wiring. Slide the spacer sleeve off of the steering column. Step4 Unscrew the ignition switch mounting screws. Pull out the ignition switch. Disconnect the wiring connector from back of the ignition switch. Simply loosen the tabs and pull it out. Step5 Insert your key into the ignition. Turn the ignition switch to the locked position. Depress the retaining pin with a small screwdriver and turn the key to the Off position to free the cylinder. Once it is free, turn the key to lock position and remove the key and key cylinder. Step 6 Install your old key cylinder into the new ignition switch assembly. Make sure the contacts in the cylinder and assembly line up. Reattach wiring to ignition switch, slide it into place, screw in mounting screws and reassemble steering wheel and switches.
The following procedure applies to vehicles that have a functional ignition switch lock cylinder (11582) and keys. If the key numbers are known, the correct key can be made. Disconnect the battery ground cable (14301). For additional information, refer to Section 14-01 .
Turn the ignition switch lock cylinder to the RUN position.
Place a 3.17-mm (1/8-inch) diameter wire pin or small drift punch in the hole in the steering column shroud under the ignition switch lock cylinder. Depress the retaining pin while pulling out on the ignition switch lock cylinder to remove it from the housing of the steering column.
Install the ignition switch lock cylinder by turning it to the RUN position and depressing the retaining pin. Insert the ignition switch lock cylinder into the steering column housing. Make sure the ignition switch lock cylinder is fully seated and aligned in the interlocking washer before turning the key to the OFF position. This will permit the retaining pin of the ignition switch lock cylinder to extend into the hole of the steering column.
Using the key, rotate the ignition switch lock cylinder to make sure of correct mechanical operation in all positions.
Disconnect battery ground cable (14301). Refer to Section 14-01 .
Remove the upper steering column shroud (3530) by removing the four or five self-tapping screws. Remove key release lever (3F527) (if equipped).
Remove lower steering column shroud.
Disconnect the ignition switch electrical connector.
Rotate ignition switch lock cylinder (11582) to the RUN position.
Remove the two screws retaining ignition switch (11572).
Disengage the ignition switch from the actuator.
Ignition Switch Lock Cylinder Housing
Slot in Lock/Column Assembly
— (Part of 11572)
Alignment Mark Installation NOTE: A new replacement ignition switch assembly will be set in the RUN position as received.
Adjust the ignition switch by sliding the carrier to the ignition switch RUN position.
Check to make sure that the ignition switch lock cylinder is in the RUN position. The RUN position is achieved by rotating the ignition switch lock cylinder approximately 90 degrees from the LOCK position.
Install the ignition switch into the actuator. It may be necessary to move the ignition switch slightly back and forth to align the ignition switch mounting holes with the lock cylinder housing threaded holes.
Install retaining screws. Tighten to 5.6-7.9 Nm (50-69 lb-in).
Connect electrical connector to ignition switch.
Connect battery ground cable. Refer to Section 14-01 .
Check ignition switch for proper function, including START and ACC positions. Also, make certain that the column is in the LOCK position.
Install upper steering column shroud.
Install the lower steering column shroud and key release lever (if equipped).
This is a bad problem, and will probably require you to replace the entire ignition system and wiring located in the mechanical end of the steering column. I feel the smoke was melting wiring due to excessive use and time. the shorted wiring or even an open wire in the steering column will most certainly keep your engine from starting. If your not familiar with 12volt systems or have a hard time with small mechanics, than find someone who can help disassemble the column and locate the wiring that needs to be replaced.