Headlight Switch Upgrade and Restoration - 88 3.2 Carrera

[grapppa]

I added a 3A fuse to terminal 58a on the headlight switch as part of electrical upgrades recommended here. I also noticed that the knob just spun on its post - as in rotating to dim/brighten the dash lights. There should be about 90 deg. rotation on its shaft - not unlimited rotation!

What I found was that the collar that secures the knob to the shaft was completely visible - you could see 6 small holes in the collar.



These six small holes are used to secure the knob to the shaft so it cannot spin because there are corresponding rubber nibs that mate into the collar!

Here you can see the rubber nibs that should go in the collar holes




So the task was then to reinsert the collar into the rubber. Not easy... You have to stretch out the rubber incrementally to allow it to seat back into the knob. I put grease on the collar to make it easier.



In order to line up the nibs with the holes I used an M6 x 1.0 x 20 screw to rotate the collar and align the nibs and holes. Eventually, all the nibs and holes aligned and it was seated properly.



One cautionary note - the graphics for the headlight icon are on the surface of the plastic - SO - if you try to polish it YOU WILL REMOVE the graphics! I made this mistake - but new ones are available from our host.