Ignition switch question

[kruzn]

Yesterday I noticed that all of my lights were out except for the turn and brake. Fuses all OK. I've traced the problem to the IGN2 circuit which is not working from the ign switch (if I jumper the red and red/white wires on the switch plug (harness side), the lights come on. Doing a continuity test on the switch itself shows that circuit is not working, so it is definitely inside the switch.

Here's the question....how do I get the switch apart? I can't even get the chrome cover off to get at the two screws that hold it to the engine bracket. Is there a secret to getting the cover off the rubber insulator? (Yes, I removed the cover screw).

If I can get it apart I'm going to try fixing it if possible...

TIA...

[kruzn]

OK...got the chrome cover off...some seriously strong rubber cement holding it on! Sprayed some silicone around the cover and pried off with screwdriver.

The switch doesn't look easy to get apart, but am still gonna try...

[kruzn]

Fixed! 

Taking the switch itself apart is NOT easy...requires drilling, etc. But after cleaning and sanding the contacts, it works great!

It lasted 15 years...maybe it'll make it another 15.......! 

[Bone]

Good job. I haven't read of one being opened-up.
Waiting for a picture or two

[kruzn]

Sorry...didn't take pics...

There is a plastic cover on the back that is "riveted" to the pot metal housing. I drilled those out and tapped for a 4-40 SS button head screw. Then there are three small Torx "security" screws that are removed to allow the switch guts to be revealed.

Once the guts are removed from the housing, you will find a plastic rotating barrel that slots into the backside of the key cylinder (which stays in the housing). That rotating barrel pops off of the contact assembly and two spring-loaded brass wipers come off with it. It is possible for these to drop out and be lost, so care must be taken.

The problem was on the contact assembly side...there were grooves worn in the brass contacts from the wipers. Fortunately, the contact plate is flat and the brass contacts are flush with the face. It was a simple matter to sand the entire face of the assembly on a flat surface using 220 grit paper until the grooves were gone and the contacts nice and shiny. I cleaned the wipers and reassembled. Good as new! Beats buying a new switch!