Legends, Guru's and Patrol Gods. I need your help pls - Old girl is giving me trouble

[gazq]

Have searched already for past similar issues here. I've tried to organise everything I have tried that I can remember.

Summary: Unreliable Starting and startup dash lights as well as gauges dont display every time when turning the key into the On position - 88 GQ TD42 with nearly half-a-million clicks on the odometer.

Problem: No startup dash warning lights, gauges, nor does the radio turn on when turning the key to On in the ignition barrel. Turning key to Start always fails to kick over the starter motor and engine when this happens. Have found that occasionally the startup dash lights and gauges will come on when returning from a failed start position and back to On position. This is consistent when it does occur. On these instances when the dash startup lights do come on I am always able to successfully start and turn over the starter motor.

Additionally, when turning the key to On I always here relays clicking in the engine bay even when the lights do not come up. When turning the key to Start position the starter relay always fires as well, but the starter motor does not actually engage.


Inspected Items:

Check battery earths and terminal connections: All ok

Checked battery voltage: Even recharged it after all my testing and issue still there

Fuses checked in the foot well kick panel: All ok

Swapped Ignition and Blower relay in foot well kick panel: No change - relay continued to click

Fusible links next to the positive side of the battery terminal checked: All ok

Starter Motor Relay: Clicks every time

Pulled Ignition switch from Ignition barrel: Could still engage and reproduce the issue using just a screw driver with the ignition switch

Attempted to bypass ignition switch by completing the starting circuit: Failed to get any relays to click - must have screwed this up. I would suck at as a thief.

Using the below diagram I tried to complete the starting circuit by running wires to 1,3,4 & 5 plug sockets and had no luck. What am I doing wrong - is there an order? I could get some clicking relays in the Accessory position when completing the circuit between 1 & 2
ignswitch.PNG

Checked for voltage for white wire with red stripe going into Ignition switch: Confirmed 12 volts supplied

Smacked fist above the instrument dash: Haha...no change, but I did feel better.

Wiggled or re-plugged in every mother f#*king wire, fuse, relay, switch I could find related to the ignition or starting of this prick. Also who in the hell was the a-hole who put the single screw that holds the ignition switch in the worlds must impossible location. I nearly lost my F-ing mind getting that tiny bastard undone.

Current conclusion: Suspect it could be the ignition switch which could be severely worn (remember nearly 500,000ks on motor) that is tormenting me - but without being able to bypass it I can't rule it out. Also I dont have a spare laying about. OR I have a melted wire/bad earth somewhere. Thought I smelt something hot once during my testing in the engine bay, but could not isolate where it was coming from.

Running out of ideas and may have to call in a pro. Any suggestions would be appreciated.

Thanks,

GazQ