Intermittent Power Window Operation Due to Broken Ignition Switch

[RAW911]

Power windows in the 87 started giving us fits. Coming back from Carmel in the late evening, put the Targa top back on and the ?@#!% windows would not work. Jiggled the key in the ignition while holding the window up switch and after several minutes finally got both sides up.

Ordered new switch and found it was a real bear to remove the original. However, following the guidelines in a YouTube Video: https://www.youtube.com/watch?v=DmBrBf0y0QU&t=62s managed to get it removed. I used a HF angled screwdriver and got the bottom screw out easily. The top one, not so much. It took hours because you could only turn the screw 10 to 20 degrees at a time before it hit on the underside of the dash.



With the old switch out, I broke it open to find the problem. The upper contact arm for "X" terminals (which powers the windows) was sprung and not closing.



You can see the points on the left side are open even though the switch is in the run/accessory position.

Plugged the new ignition switch to the wiring harness and it operates the windows with no problem.

However, I wanted to make sure the upper screw for the switch would be easy to reassemble and easier to remove next time. Therefore, brazed a washer onto a 3mm-7 pitch screw and then ground down the washer to fit into the hole on the switch.




Switch with Stock Screw



Switch with Stock Screw in Place



Stock and Modified Screws



Modified Screw in Place

Now everything works as it should.