After months of having difficulty starting the Montero, the other morning, it finally stopped starting. After isolating the fault to the ignition switch & buying a replacement at the parts store (actually an OEM mitsu part p/n MB903639) I went ahead and replaced it. This is how I did it for future reference...

Tools needed:
Very Small Phillips Screw driver (6" total length)
Small Phillips Screw driver (9" total length)
Leatherman Knife with phillips screw driver.

Here's the bottom cover of the steering column. Notice the 5 holes in it where the screws are that hold it in place. The screw in the hole closest to the camera screws into the upper cover. The other 4 holes screw into the steering column.


After removing the bottom cover, you can see the ignition switch (on left of the picture below) and the lock core.

The small 3/16" hole just below the 'RED WIRE COVER' is the lock core release. To remove the lock core, I inserted the key into the core, turned it to the ON position and depressed the brass piece in the hole to release the core from the steering column. (see below)

Once released, I simply pulled the core out completely and set it on the driver side floor.

Next, I used the 3 different phillips screw drivers in combination to slowly and carefully unscrew the 2 screws holding the ignition switch in place. The switch is the part attached to a blue electrical connector in the picture above & below.


I disconnected the cable from the switch and and then replaced the switch with the one I bought from the parts store. Interestingly enough this part came in an aftermarket manufacturers box but inside was an OEM switch from Mitsubishi p/n MB903639

Next, I simply reassembled everything and presto, I can start the Monty again! <img src="/forums/images/graemlins/kewl.gif" alt="" />

Just did this to my 95. Got the switch from Autozone. Opened the box and it was also a Mitsubishi part, in a Mitsubishi bag. <img src="/forums/images/graemlins/kewl.gif" alt="" />

<img src="/forums/images/graemlins/cheers.gif" alt="" /> <img src="/forums/images/graemlins/rodent.gif" alt="" />

Yup, where I got mine too. <img src="/forums/images/graemlins/kewl.gif" alt="" />

On my 94, some times (50% to 60% of the time) when the ignition switch is engaged nothing happens - engine does not turn over, no click of the starter, etc...

After engaging the ignition switch multiple times, the engine will start turning over and fire.

I thought the problem had to do with the neutral safety switch but wondering if maybe the ignition switch is going south.

How did you determine the problem was with the switch?

Thanks,

~ Jon

Twas a partially edumacated guess on my part. i.e. WAG. <img src="/forums/images/graemlins/wink.gif" alt="" /> <img src="/forums/images/graemlins/lol.gif" alt="" />

Yea this is a common issue, Replaced this switch on both the Gen2's that I have owned.

Also If your feeling lucky you can try to take the switch apart and clean the contacts. I had limited success wit this method..

During disassembly, be very careful with the 2 spring loaded bb sized ball bearings that shoot out when you open it. Additionally watch out for the entire switch assembly falling apart during disassembly. <img src="/forums/images/graemlins/shiner.gif" alt="" />

Yeah, been there, tried that. I disassembled mine to see if I could determine where the switch failed. Unfortunately, I couldn't see a clear indication of where the contacts were broken or worn beyond their working limits. <img src="/forums/images/graemlins/cheers.gif" alt="" />

i changed the switch and the cylinder and still had problems turned out to be the middle drive that goes from the cylinder and the switch so id shaved the switch and rolled it a little clockwise and cured the problem

When mine was in near total failure mode, if it didn't crank right off the bat, some upward pressure on the key would do the trick.

<img src="/forums/images/graemlins/cheers.gif" alt="" /> <img src="/forums/images/graemlins/rodent.gif" alt="" />

There was a thread several months ago about wiring up a starter relay to fix the common no-start problem - the ignition switch wears and has problems getting enough power to the starter to kick it, especially when the starter is older. Wiring in a starter relay would likely solve the problem without replacing the ignition switch, plus prevent it from happening again in the future.

I'm not saying that replacing the ignition switch isn't an appropriate repair, just that there's more than one way to skin a cat. <img src="/forums/images/graemlins/smile.gif" alt="" />