Yeah, after going through this and learning how common this issue appears to be, I think I'm gonna grab one out of a junkyard for a few bucks as a backup. Now that I know what to do, it's about a 10 minute job to switch it out, so it'll be good to be prepared...I don't think it would be worth it to manufacture as there are so many of them available for cheap....
I'm having a problem with my gauges. They work when my key is in the start position but once I let the key return to on they go dead. If I take my key a twist it slightly to the start position they come back on and work fine. Just wondering if its the pin or the actual key cylinder
Buy a Hybrid... My Jeep needs the gas!
If the Jeep starts the ignition switch actuator pin should be fine as it's turning the switch all the way. I'd suspect the switch. I'd remove the switch and turn it with a screwdriver to see if it behaves the same. You'd be able to see the pin with the switch removed so could take a look at that at the same time.
It could be the pin but more likely the switch itself. It is similar to what the guy in post #6 had but a different set of contacts. One set of contacts in the switch works the cluster & is supposed to power the cluster through fuse 10 in the block behind the glove box when in start & run. It apparently is not maintaining contact in the run position. The switch is not part of the key cylinder. Look at the video in post #1. Replacing the switch is the same procedure as the actuator pin. When you have it apart you can check the pin to see if it is cracked but if it looks good I would say the switch needs replacing. (Not a bad time to do the pin as a preventive measure.)
Edit: Jonny you are too quick! & a very good way to test it.
When I searched I found tons of people with the same problem. I wanted to post the video Dorman made for the fix. The nut gobblers at the dealer will say you need to replace the whole steering column. Lucky for us Dorman did a little research and helped us out.
I started the Jeep up heading to work, and thought the key turned funny. After the other crew left at shift change I went to move the Jeep since my station doesn't have enough parking spots when both crews are there. I turned the key and nothing happend. The rotation was off as well.
To pull it apart you will need
Phillips screw driver.
T-10 Security bit (center hole).
Driver for above bits.
When I pulled it apart I found one of the stupidest designs ever.
Broken part and Box (number) for replacment from NAPA.
In a jam you could start your rig with a flat head screw driver once the above part is out.
Promo video from Dorman with step by step instructions.
I hope that helps the next poor sucker that gets stuck someplace.
This helped me tremendously!! I was having an issue where my TJ would intermittently start (new battery, no corrosion on cables, etc) & it really had me stumped. I started thinking it had something to do with the ignition and after searching for a bit I came across this threat. My actuator pin looked just like yours, with the metal broken off at the "tip". I went to NAPA with the part number you posted and $46 later, I had the part & got it fixed!
Also just wanted to add that I tried using a flathead screwdriver to start the jeep by inserting it into the black ignition switch just fot sh!ts & giggles (while I had everything apart I figured why not?), and IT WORKED!! I thought that was pretty cool.
Again, THANK YOU to the OP ...my fiance will now be much happier with the Jeep now, lol
2001 Sport 4.0, 5-speed
D30/D44, 31x10.5 BFG KM2 Mud Terrains on stock 15" Canyon wheels
OK, so I'm hoping someone with experience might be able to help me out with a puzzle
I went to start my '04 TJ yesterday, but the key would not turn far enough forward to start the Jeep. The key easily turns to accessory and run positions, but not to start. So I assumed either the actuator pin or ignition switch were failed. The actuator pin did not appear broken, so I tried turning it with the lock cylinder while everything was disconnected from the steering column; it turned and the Jeep started normally. I reassembled everything, and tried again. No go. The key will not turn far enough forward. So, I took the lock cylinder back out and inspected the inside, and everything looks fine (nothing broken or worn).
I thought about buying a new ignition switch and actuator pin assembly just to rule that out, but I would not think either is the problem since it functions when removed from the steering column. The lock cylinder does not appear broken, but I don't really know what a bad one would look like
Does anyone out there have any thoughts or suggestions on how to proceed?