Ignition Switch Issues

The student pilot was doing an engine run prior to flight. Was unable on the first try to complete the magneto check as the key would not turn from the both position to the left/right/off position. After shutdown, the student was able to select off on the switch. The switch that was installed (p/n 103572101) included a push-to-start function. Found the switch sticking internally and replaced it with a new push-to-start switch.

Editorial Staff

Thursday, March 22, 2018 at 12:00 AM ET

Verified

Key Takeaways:

A variety of aircraft models, including Cessna, Diamond, Grop, and Piper, are experiencing diverse malfunctions with their ignition and start switches.
Reported issues range from switches sticking, failing to turn, unintended starter engagement, requiring excessive force to operate, and internal electrical failures such as intermittent grounding or smoke emission.
These ignition switch problems occur across different manufacturers and at varying operational times, from as low as 32 hours to over 2800 hours.

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Cessna 182T Skylane
Broken Ignition Switch

Ignition switch (p/n C2925010106) could be rotated counter-clockwise past the “off” position and engage the starter.

Part total time: 697.0 hours

Diamond DA20C1
Failed Ignition Switch

Part total time: 2800.0 hours

Diamond DA20C1
Inoperative Ignition Switch

The aircraft was experiencing starting issues. The ignition and start switch, a turn and push-to-start was not working properly. If the switch was not held hard over in the start position before pushing on the switch, it would not work. It also required a lot of force to push in and get it to work.

Part total time: 32.0 hours

Diamond DA20C1
Failed Ignition Switch

The student pilot was doing an engine run prior to flight. Was unable on the first try to complete the magneto check, as the key would not turn from the both position to the left/right/off position. After shutdown, the student was able to select off on the switch. The switch that was installed (p/n 103572101) -was a switch with a push to start function. Found the switch sticking internally & replaced it with a new push to start switch.

Part total time: 2800.0 hours

Grop G102A
Smoke From The Switch

Pilot reported seeing smoke coming from the switch (p/n 103572101) on startup. Engine shutdown and aircraft routed to maintenance. No loose wires or connections found at switch area. Can smell burned electronics inside switch. Switch replaced and system operated normally. Aircraft returned to service.

Part total time: 1732.0 hours

Piper PA-28-161 Warrior II/III
Worn Ignition Switch

Pilot reported engine roughness. Ground runs were mixed; sometimes it would run fine. Troubleshooting led to intermittent grounding at key switch (p/n 103572001). Key switch replaced. Old key switch back was removed and it was discovered the switch was intermittently grounding internally.

Part total time: Unknown