ignition switch repair

[Fred S]

Dave,

I have what sounds like a similar switch. It has 2 tabs on the back holding an insulated piece. I was able to slightly bend the tabs, to get the insulated piece out. Inside was a bar, that made contact with 2 contacts when the key was turned. I was able to clean everything, stretch the spring that puts pressure on the bar, and reassemble. So far, so good, but I don't think the tabs will bend again without breaking.

[Synchro909]

I've had a similar issue with a modern aftermarket plain (non pop out) switch. I didn't bother trying to take it apart. I supposed that the problem was related to the fact that the back of it along with the two posts was loose. When I held the back onto the body of the switch, everything worked reliably so I mixed some epoxy putty and forced it into the gaps created by the looseness. I then clamped the back tighter onto the body, squeezing some of the putty out again and built up enough putty between the posts to hold it all together. Once it had set, all was good and there have been no issues since.
When on loooong tours with only my wife (up to 10,000 miles at a time), I carry a toggle switch like the one for the driving lights which could also serve as an ignition switch if need be. I chose a switch that is also able to stand in as a turn signal switch. One part, several uses - less spares to carry.

[BILL WILLIAMSON]

Originally Posted by Synchro909

I've had a similar issue with a modern aftermarket plain (non pop out) switch. I didn't bother trying to take it apart. I supposed that the problem was related to the fact that the back of it along with the two posts was loose. When I held the back onto the body of the switch, everything worked reliably so I mixed some epoxy putty and forced it into the gaps created by the looseness. I then clamped the back tighter onto the body, squeezing some of the putty out again and built up enough putty between the posts to hold it all together. Once it had set, all was good and there have been no issues since.
When on loooong tours with only my wife (up to 10,000 miles at a time), I carry a toggle switch like the one for the driving lights which could also serve as an ignition switch if need be. I chose a switch that is also able to stand in as a turn signal switch. One part, several uses - less spares to carry.

Synchro,
If I were touring WAAAAY out in your OUTBACK, I'd tow a SPARE CAR---LOL
Bill Worry