Headlight switch fixed... extra wire? Help!
 

Okay, first of all, when I say "fixed" it's in a MacGyver kinda way.

Since I've had my car, I haven't had high beams. I've assumed it was a problem with the turn signal/high beam switch, which is prone to going out on our cars. I went to the STS at Streets of Willow and everything was fine. Used my lights on Saturday, and on Sunday morning. We went to leave at 6pm on Sunday... no headlights. Damn. Drove the two hours home with yellow fog lights (that's a whole other story).

Tested my pull-out headlight switch, I had continuity from pin 75 to 56 with the switch pulled all the way out. So that switch is okay.

So I had to check the switch on the steering column... I didn't want to have to remove the steering wheel, but it was inevitable (there are some screws holding the steering column cover on that can only be accessed after removing the wheel).

Finally got to the suspected problem switch, and here is what it looked like:
http://forums.pelicanparts.com/uploa...1265571536.jpg

So if I understand correctly, the thing that looks like a turd is a melted plastic spacer preventing contact with the high beam contact. And contact between the top two contacts (one of which is the short little one) is for regular headlights.

When I move my lever none of these metal tabs move, which I'm pretty sure means the switch is broken and needs to be replaced. I'm cheap, so I'm not ready to buy one. Using a screwdriver to move the tabs I was able to get my headlights on, but still not the brights. Okay, so the brights have anohter issue, I'll deal with that another time. Here's my MacGyver fix:
http://forums.pelicanparts.com/uploa...1265572139.jpg

Hey, it's free!!!

Now my problem, I have an extra wire, and can't remember where it came from:
http://forums.pelicanparts.com/uploa...1265572437.jpg

Looks like the ground tab for the horn.

I don't think so... where would it connect to? The metal strip in the pic rubs against the metal ring on the base of the steering wheel assembly, and there are two wire connectors inside the wheel to connect to the horn switch.

Well, now that I think about it, if there are two wires to connect to the horn switch there must be two connection points to the wheel assembly, but I don't see where that would be. Also, I don't see any extra screws laying around, so I assume it goes to something I've already connected, or something I'm about to connect.

It attaches to one of the screws holes holds the lower clamshell in place. Place the wire between the clamshell and the screw.

Bentley Porsche 911SC Service Manual>
900 Electrical System- General>
960 Electrical Switches, Interior Lighting, Cruise Control>
960-6 & 960-7, Streering column switches, removing and installing>
To Remove turn signal switch from column>
Installation is reverse of removal>
"When installing steering column covers, be sure to anchor ground wire under lower right cover screw."

Would have been easier to scan it!

Oh Yeah, steering wheel to column torque= 36 ft-lbs

sure has a lot of shavings in that lower cover...

Okay, I decided to put it here, based on the bends in the wire, seems to go along with what everybody posted while I was in the garage:

http://forums.pelicanparts.com/uploa...1265579734.jpg

I think the shavings are from the metal strip that rubs on the bottom of the steering wheel, if you look at the pic above it's a bit damaged, starting to wear through, ditto on the base of the streering wheel.

Appreciate the advice!

That is correct.