cambob

This is on a 94, 4runner, 3.0.

The symptoms:
Sometimes when driving, total cut out of ignition system. No lights (dash and cab), engine dies, nothing. Sometimes when you turn the key, you get absolutely nothing on the dash, accessories don't work (locks, windows, radio). Other times, you get the dash lights, everything seems normal, go to start and you hear a relay click, then lights go out and no start. On rare occasions, everything works as it should.

Things I tested:
Ignition switch tests fine for all positions, except for when key is turned to start position.
Wiring is all jacked up due to PO's bad install of remote start - I used Wago clips to fix wiring, test ports say connections are good. I know those aren't the best option, but I tried soldering in that little space and it was ugly.

This truck has had intermittent problems with the wiring and ignition switch. I replaced the switch a little over a year ago. I'd like to say its just a switch, but for a second to go bad that quickly, I'm thinking there is something else going on. The FSM mentions the integration relay and shows it on the drivers kick panel. I'd like to test it all, but I can't really find the plug they are talking about.

Is the relay behind the entire fuse panel? And, since sometimes I don't even get a response from the ignition when turned to the acc position, but it tests fine there, could that mean that power into the switch is bad?

wyoming9

iTrader: (1)

Sounds like you need to upgrade you grounds and then go from there.

The thing about hacked harnesses you will have issues till it is repaired correct.

cambob

All the grounds are intact and in really good shape actually. No signs of corrosion. I'm going to clean the connection points. what do you mean by upgarde the grounds? new connectors or new wire? I spent some time practicing my solder skills today. Tomorrow Ill attempt a more legit wire repair. New switch on the way.

wyoming9

iTrader: (1)

All new cables and ends.

I have found these vehicles tend to have to small battery cables from the start.

even the early nineties vehicles are getting old these things wear.

I have cured no end of starting and charging issues just up sizing the electrical cables.

Good luck with this!!

cambob

Okay all soldered up. Grounds cleaned. Soldering isn't the prettiest but my multimeter says the connections are good. Started right up. Turned it off and tried again and got a di-di-di sound. Sort of like card in wheel spokes but really fast. Tried again, it started. What the hell would be making that sound? Starter I'm guessing? It was almost like a starter not catching right.