Headlight Switch Removal -- stumped

[PSJoyce]

Headlight Switch Removal -- stumped


I read all the posts and procedures on how to add a fuse to the dash lights of my 1985 911. An easy, 10 minute project…

Didn’t quite work out that way.

First, I was stumped by a cylindrical nut that looked to be treaded on the shaft of the switch. The Bentley manual and previous contributors described a normal six-sided nut. I couldn’t grab it well enough with a needle nosed pliers, and didn’t want to destroy it, without having a back-up, using vise grips. Any ideas?





Next, I tried to back out the switch, hoping I’d have enough room to access the correct terminal. First, my pin tool broke a pin trying to turn the lock ring, and then the ring shattered when trying to rotate by tapping on a pick in one of the holes.





Its not clear on the PET what the part number is – is this OEM-90015102602, washer? Is there a substitute for this part?

Thanks

Paul

[ianc]

My recollection of this is that the knob itself just turns CCW off the switch shaft (without removing the little plastic cover with the pic of the light on it), then you can turn the locking ring off. I've always used needle nose pliers in the holes on the locking ring and had success, but it looks like you have\had a very tight one. (no pun intended).

Cannot help you with the replacement locking ring, but I'm sure someone else will, and also correct me if I'm misremembering this. Good luck,

ianc

[PSJoyce]

Thanks ianc,

You're right -- I just found this older post on removing the knob, from "Bob's Flat-Six" in 2002.

"I'll repeat it so a searcher in the future will have it right here.
The headlight switch is removed by pulling the lights into the on
position. Theres a hole in the stalk that you can put a small screwdriver
thru to hold the shaft and back off the threaded knob, turning to the left."

The Bentley must have been describing a newer car -- I'll give the small screwdriver through the hole trick a try.

Thanks again

Paul

[john walker's workshop]

there's a hole through the shaft just under the knob. stick something in there to keep the shaft from turning, then twist off the knob. trying to remove a tight knob can damage the switch unless the shaft is held properly. later switches have a hex nut under the plastic insert.

[burgermeister]

Why remove the switch?
I was able to use needle nose pliers wrapped in duct tape to pull the connector off the switch and to put the new one on. It's the black / blue wire, about the 10:00 position if viewed from the driver's vantage. I think I had to pull 1 or 2 other connectors to get a clean shot, but it was not all that difficult once I contorted myself into the proper position.
Edit: Disconnect Battery before bringing needle nose pliers near ignition switch!

[PSJoyce]

My car has the triangular metal support for the hood latch, which really blocks access. I considered just contorting and reaching around and in, but the potential for bad things happening was too high,

I may give it a try, though, especially now that I know where to look. I've got a new lock-ring on the way, so I'm hoping to be able to check this project off

First thing I do is disconnect the negative lead to the battery.

Thanks

Paul