'05 hesitates to start

my '05 Tacoma has over 320k miles. I have a brand new battery, the starter and alternator tested good but when I turn the key in the ignition it hesitates to start and in one case did not start. NOTE: While the truck is running I can remove the key from the ignition.
Any advice would be greatly appreciated!
Thanks, John

 

Do you have other keys?
Have you tried them to see if issue still exists?
The taking the key out does sound good at all, I’ll let other chime in on that

 

Which is happening? No crank or cranks but doesn’t start when you turn the key.

 

I’d venture to guess it is the ignition switch.
But guessing is not the correct way to diagnose it.
The tumblers in the key could be worn. Or the key could be worn.
So we can’t go off the ignition switch based on the key being able to be pulled out.

If you can answer @Waasheem question, we can help you further.

 

@Waasheem I'm not sure the key issue is the real problem. I've been able to remove the key while the truck is still running for quite sometime. The other morning my truck would not start. I jumped it and drove it to an auto shop to test the battery (even thought I just installed a new one a couple weeks ago). The battery tested good along with the alternator and starter. Ever since, the truck will start but not it hesitates. So my thought is maybe an ignition issue of course I'm no mechanic.

 

Put a voltmeter on the little control wire at the starter and see if you've got 12 volts there when the no-crank happens

If no, check the ignition switch

If yes might be a bad reman starter

 

@b_r_o How do I "Check the ignition switch"? and what result will point to a "bad reman starter"? Sorry for my ignorance. I have limited mechanical experience.
Thanks!

 

With the key in the "crank" position there should be power at the little control wire on the starter.

If the power isn't getting there then the issue is between the key and the starter. Since you mentioned you can take the key out of the ignition it is kinda suspect. But you have to pull the column covers and test for power in and out of the electrical part of the ignition switch. You'll need a wiring diagram and some skill with a voltmeter

If the power is getting there the starter should be spinning.

Also need to be closely looking at the big cable connections (power/ground) between battery, frame, engine block, starter, alternator, etc. They need to be snug, pull on them, stress them around and make sure they're tight

 

@b_r_o Thanks for the advice! I'll look into it.

 

I should expand this. If it doesn’t crank do you hear nothing, a single click, or a rapid fire clicking?

It’s helpful to know what the symptoms are to be able to provide direction to diagnose. Trying to diagnose with a keyboard is difficult enough as is. Without necessary information nearly impossible.

 

By testing the resistance of the ignition switch and related wiring, with the power off of course, you can find bad connections, not much expertise required.
I'd be willing to bet the ignition switch is shot. With the mileage, certainly can't complain.
A multimeter costs less than $10 and can save you a lot of time and trouble.

 

@Waasheem Thanks. Maybe a mechanic would be better to diagnose the problem.

 

I vote ignition switch

 

I vote I’m lazy.
Crawling under a truck isn’t where I’d start. Remember, I’m lazy. I’d start with the easy stuff first.

I’d start at the sta relay and see what is and isn’t getting power.

I can’t access diagrams right now. I’m busy. But here is a little diag we went through a year ago.

Start with pins 1 an 5
https://www.tacomaworld.com/threads...acoma-no-start-no-crank.744301/#post-26498533

 

@TnShooter Thanks for the diagram!