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Old 09-03-2011, 08:44 PM   #1
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Intermittent Starting Problem, Please Help!

Hello all,

I have a very frustrating issue with my 2004 Workhorse Chassis. The truck will refuse to start and there is no power sent to the dash (the trip computer will not light up).

This only seems to happen after I have driven the truck for a while. If I let it sit overnight it will start okay.

The batteries are all okay, everything (headlights, AC fans, Radio) that runs on the chassis battery will still work fine when the truck will not start. The ignition switch seems to be working because the AC fans (which are not able to run while the ignition is off) work when I turn the key.

My hazard lights will work but the lights on the dash will not if the problem is occurring. Has anyone had a similar problem? Any suggestions/help is appreciated as I really need to get this truck up and running ASAP. Please let me know if I am leaving anything out that may help diagnose the problem. Thank you!
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Old 09-03-2011, 08:45 PM   #2
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I forgot to add that nothing happens at all when I turn the key. Normally I will hear a clicking sound and the dash will light up, but I hear nothing. The car will not attempt to crank....
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Old 09-03-2011, 10:11 PM   #3
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Originally Posted by cefiro View Post
I forgot to add that nothing happens at all when I turn the key. Normally I will hear a clicking sound and the dash will light up, but I hear nothing. The car will not attempt to crank....
I'm not an expert I'm sure one will be along---but this information would make me think harder about the ignition switch----if it used to click and now does not---then it may be missing a contact along the way. UNless the "click" you mention comes from another source, of course.
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Old 09-04-2011, 02:32 PM   #4
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I agree that the ignition switch may be suspect. I remember some topics in the past years discussing switch problems. I think one issue is that some motorhome builders wire up additional circuits to contacts on the ignition switch which does not have the current rating required. So after a while they begin to work intermittently.

Do a search of this Workhorse forum for "ignition switch" and you may find the answer to your problem or clues where to look.

Good luck,
Bill
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Old 09-04-2011, 08:31 PM   #5
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Ignition switch fix
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Old 09-04-2011, 08:53 PM   #6
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Please note: the link to Dale's site for the IGN SWITCH "fix" applies ONLY if you have a P32 chassis. The W -series does not seem to be prone to this problem. The OP only stated he has a Workhorse chassis.......
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Old 09-04-2011, 09:39 PM   #7
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When my ignition switch went, the contacts literally burn up (no fire) and the plastic starts to melt. I was able to buy a surplus Workhorse kit on eBay and it included two relays so I would say the DIY explanation takes care of the biggest problem but not the whole problem.

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Old 09-04-2011, 09:50 PM   #8
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Please note: the link to Dale's site for the IGN SWITCH "fix" applies ONLY if you have a P32 chassis. The W -series does not seem to be prone to this problem. The OP only stated he has a Workhorse chassis.......
Correct. What's not in evidence here is whether the OP has a P series or a W series.

I exhibited similar symptoms with my vehicle and found it to be a bad starter.
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Old 09-04-2011, 11:15 PM   #9
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If it's a 454 they had a problem with the starter over heating. Corvettes had this problem and they placed a shield between the starter and the block. My 454 does it all the time.
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