For some time now my 91 3.0 has had a starting problem.

Sometimes I get in and it starts right up, no problems. Other times, I have to keep "bumping" the key switch to get it to start, (occasionally as many as 25-30 times <img src="/forums/images/graemlins/angry.gif" alt="" />!)

I've changed the starter and battery, they both needed it, but the problem persists. Anybody have any ideas? I'm at my wits end.

BTW, I've checked the pos and neg cables and both are in good shape physically and have no resistance on the VOM. I've also checked the ground system and all the connections are tight. Once started the truck runs well. <img src="/forums/images/graemlins/patriot.gif" alt="" />

Mine does the same thing. Occasionally, I turn the key, and.... nothing. Keep turning it, and it's business as usual. It appears to me it's the switch itself. It just hasn't gotten bad enough to spend $ on replacing it <img src="/forums/images/graemlins/notooth.gif" alt="" />

we dont all speak Texanese, so clarify this:

you turn the key and nothing happens
OR
you turn the key and the motors turn, but doesnt start.

?????????????

Sorry, ya'll just have to excuse me.I forget, we DO talk funny down here. (If ya think this is bad, ya ought to hear us when we're out working the cattle. Even I have a hard time occassionally.)

What I'm saying is that when I turn the key to the start position I get only a click. The click appears to be coming from around the passenger side kick panel. If I repeatedly turn the key from the "ON" position to the "Start" position it will eventually crank and start normally. Does that help clarifiy?

I don't know if this is your problem but I will bet it's the other guys problem-- There is a park switch inside the auto shifter that tells the truck it is in park. This switch gets gunked up and sometimes does not let the truck roll over. Next time your truck doesn't start just wiggle the shifter in the park position and see if it rolls over. You can with minimal work- take the switch out and clean it. Most of us that have had the trucks for a while have done this. <img src="/forums/images/graemlins/kewl.gif" alt="" />

GPB,
My '92 was doing the same for awhile. Finally one day it wouldn't turn over at all. I crawled underneath to look at the starter, and one of the wires was hanging off the starter. <img src="/forums/images/graemlins/smile.gif" alt="" /> It must have been just barely touching before, and caused the intermittent click/start issue. Snapped the wire back on, and fine ever since. HOPEFULLY yours will be as simple.

Had that out already, it was relatively clean. And the PRNDL switch is in adjustment. It's the ignition switch, I know it. It has to be. Only thing left. Well, only thing except a bad spot in the starter solenoid winding. But, it doesn't sound like it to me. Sometimes, mine will go weeks without a problem. Does it once, then won't happen again for another week. Like I said above, it hasn't let me down, so I'll let it get worse before I replace the switch <img src="/forums/images/graemlins/notooth.gif" alt="" />

When it's happening[not cranking], drop the steering column covers to get at the ign. switch wiring. Jump the main hot wire and the starter input wire terminal[power that goes out from the switch to the starter motor] If the starter now merrily cranks away, then your ign.switch is acting up intermittently. Cheap part, easy to change, and you don't need to mess with the ign. lock cylinder, just replace the electrical portion.
If you have an automatic Montero, it could be the Park/neutral switch. Even if it's in adjustment, they DO go bad. I just replaced mine a few weeks ago for a no crank problem. I got one shot trying to start the truck in Neutral instead of Park, it did start, but then the switch died completely at the next time I needed to start the truck later that day, with neither Park or Neutral working.

Yes. That is the same area as the starter. Would you say it is a "clunk" instead of a "click"
You might have bad connections.... weak solinoid .... ?

c'mon guys, what do you think?

Well, I had that happen years ago and it was not the ignition switch. I still have that trouble but too lazy to fix it now. It is the wire to the starter, the small one. You most likely have to fix the connector that hooks to the wire.

When this problem happens now, I just have to reach under and get my hand a little greasy move the connection and it will start, no monkeying with the key at all.

Now on mine it is the connection at the starter, you may have to check that wire all the way back to where you can find a corroded or cut or something odd.