Ignition switch - wire connection

[lucalotti]

Hello,

I am Luca, and I am writing from Rome. I am a happy owner of Transit 1600 OHC 1978. It is a 9 seat Van, light blue as the sky.

During December someone tried to steal the van. The thief disconnected rudely the wires from the ignition switch.
Should be simple to weld them back, but I do not know the colour/pin to weld the wires; unfortunately all the spare parts FORD reseller and FORD workshop, archived the old workshop manual into the rubbish bin. (:-((
So, I did not find any FORD related that helped me; the only solution proposed was to order a new ignition switch for 70 Euro!!
I also found on the internet some Haynes Ford workshop manual of sierra and Fiesta, but they did not help me.

Yesterday night looking on the internet I met you. (:-))

I will give you the wires colour and the pin number I found on the ignition switch, hoping one of you could help me.

Wire colour 6 wires:
black
red
black/yellow
yellow
brown
brown/yellow

Pin letter/number nr. 6 :

R
P
30
90
91
??

I will appreciate any kind of help, moral as well, and let me send you Happy new year and Best Regards.

Ciao Luca

Do not hesitate to contact me in case you want come in Rome, I will try to help you, at least for a beer.

[FredTransit]

Welcome lucalotti, I am sorry about what happened to your minbus. Is the van Mk1 or Mk2? There were both in 1978. I can't help with wiring diagrams, but I know somebody on here will. Also, is it petrol or diesel, originally if the engine has been changed.

[MrMPuk]

This is all I have, doubt it will help much though as the terminals aren't numbered,

[Luke]

R - yellow - think this is just for the radio
P - red or pink/red ?
30 - red
90 - brown
91 - brown/yellow
50 - black/yellow

should be 15 - black??

Not 100% sure but see how you get on!!!

[Caulky]

My diagrams agree with Luke.
The red going to pin 30 is the large one 4.5 mm.
The other red on pin P is O.75 mm.
The yellow is a feed for the inline radio-fuse.....position 1, so you dont need the ignition switched on.
The black on pin 15 splits outside of the connector, one going to Fuse 11 and the other to the ballast resistor.

This only applies to the petrol models, diesels are different beasts.

[lucalotti]

Hello,

Fred, my minibus is MK2 and it is petrol.

MrMpuck, yes, it is quite complicated to reach the end of each cable, and all of this cables are short and connected to 6 pin plug hide under the dashboard (I am not sure of this term).

Luke, Caulky this is could be the right connection :

30 - Red 4.5 mm
P - Black 4.5 mm
R - yellow 0.75 mm
90 - Brown 0.75 mm
91 - Brown/yellow 0.75 mm

50/15 - Black/Yellow 3 mm

what do you think, could it make sense, or it will burn "Sanitario" my minivan


Thank you for your attention .

ciao luca

[Caulky]

Luca,

I realise your task is not easy. I will try to describe the ignition switch wiring.
This is taken from the Haynes Ford Transit (petrol) Owners Workshop Manual, 1978 to 1986....all inline engines.

The wiring is spread between various pages, depending on the function...ignition, lights, other stuff, etc.

There are also differences between models regarding extras, optional or alternative items. (tachograph, automatic, etc).
BUT the wiring is the same. I think. [there is a pin number difference between standard/automatic ignition switch, one is R,P, 15, 50, 30...the other is R, P, 90, 91, 15, 50, 30. ]
The ignition switch just switches battery +VE to various components, depending on the position.

In position O (off) red pin 30 is connected to pin P--->2 x 0.75 mm red wires to connectors (both not connected to anything)

In position 1 red (pin 30) is connected to pin P and pin R (radio, yellow) and nothing else.

In position 2 red (pin 30) is connected to all pins except pin 50. and pinP. (ignition on).

Position 3 connects red (pin 30) as in position 2, BUT also connects pin 50 the solenoid connection, (starter motor cranking). Black/Yellow wire.

P 2 x RED 0.75 mm. (both not connected externally) *note: internally in the switch it IS connected to pin 30.

R Yellow 0.75 mm ---->radio inline fuse. (not through a connector socket)

15 2 x BLACK : 1 2.0 mm--->F11--->voltage stabilizer/ignition light. (black/yellow *colour change from Black).
: 1 0.75 mm--->Bulkhead connector--->ballast resistor.

50 Black/yellow 3.0 mm --->Bulkhead connector--->Starter motor solenoid.

30 RED 4.5 mm--->F1 (This is also connected to battery +ve via connectors and other components, etc)

91 Brown/Yellow ) 0.75 mm--->through bulkhead to an inline connector---colour change to Brown/Green--->Brake pressure switch.

90 Brown 0.75 mm--->lighting/wiper switch.

In position 2 (ignition on) the only important thing is that the Black/Yellow wire is NOT connected (solenoid). Pin 50.

And in position 1 ONLY the radio wire is connected. Of course in position 0 nothing is connected.
I hope this helps and that it is accurate.

Ciao for now,
Caulky.

[lucalotti]

Hello,

thank you for your help; finally I sort the switch ignition problem.

Before to start the welding I test the connection and if the three switch mode worked properly.

Then I welded the wires as for the following scheme:

90 Brake Pressure switch - Brown (90 and 91 only on 3rd switch position are connected)
91 Brake Pressure switch - Brown Yellow
15 All the electric services - Black
50 Starter Motor Solenoid - Black Yellow
R Radio - Yellow
30 Main Positive - RED

This works fine, but the thief broken the starter motor solenoid. I tried to charge it directly but nothing happen.

Now I have to take out the starter motor to check what it is broken.

Could you please let me know the cost of solenoid from your side, original, commercial and refurbished one? Here the Ford spare parts are really expensive, for example a new lockheed brake pump with pressure switch cost around 500 Euro, and I used the lockheed kit to rebuild my pump for 70 Euro.

Ciao Luca

[FredTransit]

Damn! Gary's literally left for Milan, and he could have brought you a new starter motor, petrol ones are about £70, Diesels £160!! I wish I had read this earlier, I have a petrol one sitting in the 'parts dept' (spare room)......