I've searched several forums and haven't seen my problem discussed.
I have a '99 F150, 5.4 Automatic, about 220,000 miles, I'm the original owner. The ignition switch stopped working the "start" function. My Son told me it wasn't working the "accessory" end either. Here's what I've done so far: removed the key switch, then removed the tumbler, cleaned and dry lubricated it (graphite) then re-installed it. Replaced both upper (Dorman) and lower (Ford OEM) actuator rods. Replaced the ignition switch (Napa), the transmission locator/neutral safety switch (Napa), the starter solenoid (also Napa). Engine starts when I jump the solenoid, but not when turning the key (starter doesn't crank, nothing happens). I removed the ignition switch from the bottom of the column and manually moved the pin, the starter cranks and engine starts. Re-installed the switch, doesn't start. I have verified that the hole in the actuator rod moves the entire distance of the slot in the bottom of the column. I measured the distance the pin on the ignition switch moves to activate the starter, then compared that to the distance the hole in the actuator rod can move. The rod can move 1/10th of an inch farther.
My Son had used the truck to run an errand, this issue surfaced when he tried to start the truck to come home. First time it's ever happened.
Anybody have any ideas?
Thanks, Phil

 

Follow-up on the ignition thing: the truck is fixed. I re-installed the original (factory) switch and the truck started right up. My best guess is that the problem started with the upper actuator rod skipping a tooth on the key switch gear, and I went the wrong way first in trying to get it fixed. Still no explanation on the replacement switch not working.