Ignition Issue?

[nodaksn3]

Subject vehicle is my 1995 FJZ80 with 318,xxx miles in Phoenix (hotter than Hell!)
Lately, when I turn the key switch to "start", there's been a slight pause before the starter "hits" and then the starter turns over quickly with no apparent drag and she then fires right away.
I replaced the contacts on the starter a couple of years ago, and before that about 10 years ago, replaced the starter with a rebuild.
Battery is ok, pleanty of juice.
Anyway, yesterday after driving it a few (15, scan gauge read 193 degrees) miles, it refused to crank over. I could hear a strong "click" from the solenoid, but the starter didn't hit. After a few minutes, I tried again, and it started fine. Later in the evening I tried again, and same thing, a pause, then the starter hit and it fired.
Any ideas? I'm thinking the ignition switch? Or is it time for another starter rebuild? I'm not good with electric issues. And yes, I've looked through my FSM.
Otherwise the truck is clean and well maintained, so even after 13 years she's a keeper.
Thanks for any advice.
Ned

 

[Wayne]

The fusible link coming off the positive battery post can cause starting problems and only cost about $12 at a dealership. If you haven't ever replaced the link I would as a PM. I would definitely do that before I replaced any other parts. However, I believe you're in the right area by looking at the solenoid contacts and ignition switch, but I would replace the fusible link regardless.

 

[nodaksn3]

Thanks Wayne, I will check it out. BTW, were you with 3rdMarDiv in '69? I was a platoon leader in the 101st when we relieved them and watched the last units leave the Rockpile. Not a fun place. My late brother had been an artillery FO with A/1/4 Marines from '68 to '69.
I'll get a fusible link right now!
Ned
Retired Maj

 

[nodaksn3]

Well that didn't work.
One thing I forgot to mention was that when running on cruise control, it sometimes hesitates when it hits a bump such as a joint in the pavement. That may indicate a loose or worn ignition switch, I think.
Any other ideas?
I hate to simply begin to switch parts!
Thanks, Ned

 

[Wayne]

Ned, the first half of my career in the Marines I was an aircraft mechanic (power plants and fuel systems on the F4 Phantom II). In '69 I was at Chu Lai air base with VMFA-122. I didn't get into the infantry until '81 (I Co, 3/1, 1st Mar Div) and retired in NOV 83.

That hesitating does sound like a break in the ignition system somewhere. I don't know if the starting issue and the hesitation are connected. They may be two separate issues. I would stick with the starting issue for now not to confuse things. Do you have a FSM? It has all the troubleshooting and testing requirements for the entire starting and ignition system. Start with the simple stuff first, e.g., battery cable connections (+ and -) for cleanliness and tightness, ignition switch to starter solenoid wire (both ends) for cleanliness and broken or loose connector, etc. Before I would open up the steering column and ignition switch I would pull the starter and inspect and repair the solenoid contacts if necessary. Good luck tracking it down and let us know what you found and what fixed it.

 

[nodaksn3]

Thanks Wayne. Yes, I have the FSM. I will pull the starter when we get back to Phoenix in the Fall. We're snowbirds and are headed back to Mass. tomorrow- hotter than heck here. The 80 stays here in the garage, we drive our old 100 back and forth. I can't bring myself to sell the 80 although I probably should-best vehicle I've ever owned.
We were out of Evans, north of Hue. Lovely spot ha, ha.

 

[Slowguy432]

Wondering if you might have a loose ground somewhere ? Those stupid things can cause issues like this -