So last week I was driving the truck and made a stop. Turned the truck off, got out and took the key with me, got back in, and the key was very hard to turn and I heard something click while starting it. Got it started, but the key didn't spring back to On like it normally does and I was forced to turn the key back so it wouldn't keep trying to engage the starter. Made it home and shut it down, and then tried the sequence agin with the same results.
My first thought was the ignition cylinder, so I put a new one in with the same result. Then I went with the 2nd option of replacing the ignition switch, and that definitely was the culprit...the new switch makes the key sequence fluid again, but I cannot get the truck to start. It seems like the key is having to be turned a little more to get to the On position, and then when I turn it to engage the ignition switch/starter, it doesn't seem to be turning as far as it used to. It's almost like the turning of the key has somehow been clocked forward a little too much, and that the rod is not pulling the ignition switch back far enough to make the electrical contact to engage the starter.
I did go down a little further into the upper steering column to be sure those four inverted E8 torx screws were tight. Using Jazzman's Steering Rack Rebuild guide, I'm pretty positive I got everything back together correctly and lined up. I even disassembled it a couple more times to be sure.
The only thing that I really couldn't check was the ignition switch rod behind the part of the upper column that can't be taken off easily while the column is still in the truck. But the sector is moving properly with the gear and lock pin.
Any idea what else it could be?
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