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Join Date: Mar 1999
Location: Cornwall-on-Hudson, New York, USA
Posts: 4,499
Easy (relatively) ignition-switch replacement

Just replaced the electrical part of the ignition switch on my 2004 Boxster, and don't let anybody tell you it can be done entirely from the driver's-side footwell while lying on your back. I was getting nowhere with the little screw (there are two, covered by easily removable mild red Loctite of some sort--lacquer thinner on a Q-Tip will dissolve it) on the clutch-pedal side of the lock assembly, though the one on the gas-pedal side was accessible from the footwell.

What you need to do is remove the left-side vent/headlight-switch unit to get at that hidden screw, and it's easy to do.

First you remove the headlight switch--pull it out and release with a small screwdriver the little brass retaining spring at the six-o'clock position on the switch, so that it pulls off entirely. Then there are three Torx-head screws holding the entire vent-panel unit on. Two are easily visible near the door jamb, but a third screw is somewhat hidden at the three-o'clock position on the recess in which the headlight switch sits.

Then pull the unit straight out; you may need the help of a putty knife to get it started since it's a tight fit.

Then disconnect the headlight-switch wiring--it pulls straight off, plus a small secondary connector for a small lightbulb, I believe--and remove the ducting that feeds the vent. It's held to the forward firewall by a single screw that you'll see right through the opening of the duct. When you drop the duct into the footwell, you'll have relatively easy access and visibility through the resulting hole in the panel.

I can't imagine how anybody gets that switch unit out without doing this, though I'm told it can be done. Don't bother trying is my advice.

__________________
Stephan Wilkinson
'83 911SC Gold-Plated Porsche
'04 replacement Boxster
Old 09-18-2008, 01:12 PM
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