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Start issue after breaking key off In ignition lock cylinder

Tiny
CHRIS CARBAUGH
  • MEMBER
  • 2006 FORD F-150
  • 5.4L
  • V8
  • 4WD
  • 133,000 MILES
Last night I accidentally tried to start the truck with the wrong key and then it broke off when I tried to remove it. I got the broken piece out of the switch, but now the starter doesn’t turn when I try to start. The battery is good and I noticed that the gauge doesn’t drop when I have the key in the start position. What have I done and how do I fix it?
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Sunday, August 4th, 2019 AT 9:55 AM

14 Replies

Tiny
SCGRANTURISMO
  • MECHANIC
  • 4,897 POSTS
Hello,

You have probably damaged the ignition switch lock cylinder which is not allowing the contacts to come into contact on the ignition switch. The problem is that if you replace the ignition switch lock cylinder with new keys the keys will have to be programmed to the Power-train Control Module. This can only be done at the dealership or a locksmith. There is another possibility, the ignition lock cylinder is attached to a plastic arm that gets pushed as the ignition key is turned and moves the ignition switch into position. This plastic arm could have been broken when you broke the key off in the lock cylinder or when getting it out. In the diagrams down below I have included an exploded diagram of the ignition system and factory testing of it. Please go through these guides and get back to us with what you are able to find out.

Thanks,
Alex
2CarPros
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Sunday, August 4th, 2019 AT 10:45 PM
Tiny
CHRIS CARBAUGH
  • MEMBER
  • 9 POSTS
Thank you.I will look into this this afternoon. The last thing I attempted yesterday was disconnecting the battery and computer for about 30 minutes. When reconnected, I still had no starter action, but heard strange noises from inside the dashboard. I assume these to be blended door movement, but I only hear them with the key in the “start” position.
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Monday, August 5th, 2019 AT 7:09 AM
Tiny
CHRIS CARBAUGH
  • MEMBER
  • 9 POSTS
Also, my local parts stores are telling me that I don’t need to visit the dealership for programming with their new lock cylinders, even though they come with “transponder” keys. I still think the starter may be the issue, since it attempted to start the first time I could turn the lock cylinder. It spun very slowly before “clicking”, making me think the battery was weak, but battery tests fine.
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Monday, August 5th, 2019 AT 7:17 AM
Tiny
CHRIS CARBAUGH
  • MEMBER
  • 9 POSTS
Now this. Resting without key in the ignition, my tester shows 9+ volts on hot cable at starter. Insert key and turn to RUN position and it shows 12+ volts. Continue into START position and voltage drops back to 9+. This has me baffled. I was a bodyman for 25 years and have dealt with plenty of collision related gremlins, but this has me beat. My instinct tells me it’s the lock cylinder/security system.
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Monday, August 5th, 2019 AT 11:19 AM
Tiny
SCGRANTURISMO
  • MECHANIC
  • 4,897 POSTS
Hello again,

You have unwanted resistance in the starting circuit somewhere that is taking 3 Volts (Electrical Pressure-Much like P.S.I. In a hose) to overcome for the currant to reach the starter. My thoughts would be in the ignition lock cylinder, since it has 1/2 of a key broken off in it, but I could be wrong. In the diagrams down below I have included a wiring diagram of your vehicle's starting system and a guide that explains how to find unwanted resistance in a circuit using the voltage drop method, which is the preferred method to use. Please go through these guides and get back to us with what you are able to find out.

Thanks,
Alex
2CarPros
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Monday, August 5th, 2019 AT 11:40 PM
Tiny
CHRIS CARBAUGH
  • MEMBER
  • 9 POSTS
Will do. Thank you. The small broken key price was easily removed and the lock cylinder seems to be working as it should. However, the little “door” the key must pass through has removed. Would that cause voltage drop?
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Tuesday, August 6th, 2019 AT 4:46 AM
Tiny
SCGRANTURISMO
  • MECHANIC
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Hello again,

Possibly, but I don't have the vehicle here in front of me. The only way to find out where the problem is is to run the tests. Please let us know what you are able to find out.

Thanks,
Alex
2CarPros
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Tuesday, August 6th, 2019 AT 6:48 AM
Tiny
CHRIS CARBAUGH
  • MEMBER
  • 9 POSTS
It was the starter. Thanks for the input though. It is appreciated.
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Tuesday, August 6th, 2019 AT 10:52 AM
Tiny
CHRIS CARBAUGH
  • MEMBER
  • 9 POSTS
So now it starts but after 10-30 seconds, the oil pressure drops to zero and internals begin knocking. Anyone want to buy a truck?
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Tuesday, August 6th, 2019 AT 11:32 AM
Tiny
SCGRANTURISMO
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Hello again,

Sorry to here about that. If you want a guide on how to replace your vehicle's oil pump and pickup tube we have that for you. Have you check the engine oil level on the dipstick? Let us know if you want the directions or not. We are here to help.

Thanks,
Alex
2CarPros
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Tuesday, August 6th, 2019 AT 3:42 PM
Tiny
CHRIS CARBAUGH
  • MEMBER
  • 9 POSTS
I would certainly appreciate any ideas! As a retired body-man, I know enough to handle collision related mechanics, and I build my engines for my older cars trucks and bikes. This thing is simply over my head. So, the first start after replacing starter was normal but took quite a while for pressure to kick in. (As long as I’ve owned it, this has never happened, but there has always been chatter from the top end.) Once it built pressure, it idled smoothly and sounded fine. Then a strange “grinding or crunching” cane up and then “ding”, then “check gauges” in the info center, followed by a total loss of pressure at the gauge, followed by audible loss of pressure. I tried a few more times, before giving up. The grinding sound comes in after about 10 seconds of smooth, quiet idle. After this sound stops it’s a matter 2-3 seconds before pressure loss. I’m stumped.
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Tuesday, August 6th, 2019 AT 8:25 PM
Tiny
SCGRANTURISMO
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Hello again,

Okay, lets start from the beginning here. What is the engine oil level from the dipstick look like?

Thanks,
Alex
2CarPros
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Wednesday, August 7th, 2019 AT 2:29 AM
Tiny
CHRIS CARBAUGH
  • MEMBER
  • 9 POSTS
Hi. It’s between the marks, dead center.
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Wednesday, August 7th, 2019 AT 5:55 AM
Tiny
SCGRANTURISMO
  • MECHANIC
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Hello again,

In the diagrams down below I have included the first set of diagrams for the removal and installation of your vehicle's oil pump and pick up tube. I will send the other set seperate in a little bit. There are a lot of steps.

Thanks,
Alex
2CarPros
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Thursday, August 8th, 2019 AT 12:43 AM

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