Ignition switch fix--mechanical
 

There seems to be a rash of ignition switch problems lately and the mechanical ones are the most expensive. The switch on my 73.5T broke and after removal of the mechanism, I discovered the dreaded "broken tab" (picture borrowed from another Pelican)
http://forums.pelicanparts.com/uploa...1300480770.jpg

Knowing that a used replacement runs around $200-300, I tried a fix that appears to be working.

Using a Dremel, the first step was to grind flat the area of the broken stub inside of the switch housing. Then, with a small drill bit and a small Dremel bit, I cut a vertacle slot in the spot where the tab had been. The slot was cut to the size of the width of one slot in the "+" that is in the back of the electrical portion of the switch. (Photo)
http://forums.pelicanparts.com/uploa...1300481201.jpg

Next, I made steel tab that fit the width of the slot in the electrical part and about double the length of the broken tab. Notice the narrowed part that will fit into the slot of the mechanical switch(photo)

http://forums.pelicanparts.com/uploa...1300481408.jpg
http://forums.pelicanparts.com/uploa...1300481429.jpg

I worked slowly and used a file to make sure the tab had a snug fit in the switch mechanism and a bit looser fit in the back of the electrical portion. When done, I used a small bit of JB weld in the slot and tapped the tab into the back of the switch mechanism and let it set up. (photo)

http://forums.pelicanparts.com/uploa...1300481570.jpg

Put it all back together, tested it with the key for turning, and reinstalled the unit. So far, all works well though my tumblers are a little sketchy and will need a new key or service on the lock itself. I'll still probably spring for a used unit just for peace of mind, but for now, it's all good.

I've thought of that fix before but as yet haven't had to try it out.
Good for you. Nice write up.

very cool fix,mine broke at the track last weekend and cost me th last couple runs,very frustrating.I found allot of used complete housings on the ads section and grabbed one of those but i like the idea here if it happens again!

Nice job......
 

Larry,

That's a pretty good and creative troubleshooting!!! I should call you now as LJ McGuiver. Did you remove the tumbler from the ignition housing? Thanks.

Tony

I went to autozone and bought a $9 black pushbutton switch and mounted it in the hole that the old securitry system when in and I start the car with the push button so that the key does not have to oppose the spring. So, key on - push button to engage starter and start car. Works awesome. However, there is no safety system. Push that button when it is running...........The damage could be pretty bad.

Ray

Hi Tony,

No, didn't remove the tumbler just the electrical part from the back. All work was done with the tumbler/lock in place.

On another note, due to the usual "unforeseen" life circumstances, I chose to sell the 73.5T, so I no longer am a Porsche owner--in fact, I divested myself of all things Porsche and have been "clean" since March. I cannot, however, break the Pelican habit and I've been visiting the forum regularly, offering a bit of help if I can. I really love this community and I've come to "know" several members, such as you, through the virtual neighborhood. I really don't feel like I belong anymore, but I still like to eavesdrop now and then. You are all a great bunch of people, and Wayne is a tremendously generous host whose generosity has made this the most respected and informative websites around.

Ossi, sorry to hear you are no longer the caretaker of that gorgeous 73.5T. On the other hand I am glad your Pelican blood is still running strong and you plan to continue to visit and contribute to the forum. You have helped me more than once on this forum and I thank you for your time and effort in helping me.

Thank you. PM sent.

Wow,..mucho thanks here, for sure......do stay with us........Best to you, Ossi!!!!


Doyle

Ray - I am glad to see I am not the only guy who decided that, if the only problem was the switch not wanting to go into the start position (at least not reliably), a pushbutton switch would do fine. My car is loud enough that hitting the button by mistake isn't going to happen.

http://forums.pelicanparts.com/uploa...1316992813.jpg

Others have scoffed at this, asserting that I am just temporizing. But it has worked fine for well over five years now.

Easy to do, and saved an awful lot of work.

My remote start switch:
http://forums.pelicanparts.com/uploa...1316997286.jpg

How to:
Remote Starter

Sherwood

I've just employed the 'slot in the ignition fix' to combat the dreaded broken tab issue. Will see how it holds up.

I've also bought all of the parts to put in a push button starter, to try and reduce the wear and tear on the switch. The only part I'm not happy with is the starter button itself. All I could find locally was a round pushbutton, that doesn't have an obvious home.

What I really want is to use something like a sunroof switch, and put it where the rear wiper control is between the fuel gauge and druck press gauge. Does anyone know if the sunroof switch is rated high enough? (Or any other thoughts?)

Al

Ha well a quick look on pelican, and the sunroof switch is NLA anyway! (Which makes me fear for my sunroof switch suddenly...)

Does anyone know of anywhere online that makes small rectangular switches that fit in the holes on the dash? Someone in this group must have had to replace their sunroof switch sometime...

You could use a lower rated switch that operates a large capacity relay.

That would probably be the best way to do it. Start buttons are cool.

The mechanical part of my switch is good but the electrical part is being held together with two part epoxy and tape. I really should change it out.

Ha, my electrical part fell apart as well. I tried the electrical tape trick, it lasted about a day. I got a new one from Porsche South (about $170 delivered), but if I had more time I could've saved 40 or 50 bones (or more) by ordering it online from the States. Don't wait til it dies!...

I picked up a 30A relay from Jaycar, as well as a pushbutton, wiring, connectors etc. I've pretty much resigned myself to cutting in to the instrument panel and sticking the button in there. Looking at it again, it won't not so bad - it looks period correct, and reasonably stealthy.

Of course, I could have just bought the 'kit' that Jaycar offers... but it was for 'Racing Use Only' - a big 'ENGINE START' button, Missile Control-style kill switch, and nice red light all mounted on a mock carbon fibre plate. Ready for mounting,... once you clear the vomit off it. I think I may have offended the shop clerk when he showed it to me and I physically recoiled and violently shook my head.

I'll be doing the same on my sc. Trying to decide if I want the switch where Sherwood put his (I have a rocker switch there that does nothing) or between the oil level and temp gauges like Walt's (but in the lower spot where Walt has a rocker. My car does not have a switch there, but I can feel a factory hole in the metal under the vinyl). There may be other factory holes under the vinyl. I have to check.

Like this one? I couldn't find the kit on their site.

Engine Start Switch

• Keyless engine start for track or street.
• Illuminated momentary action pushbutton
• Rated for 12VDC 50A ;)
• Mounting hole 22mm

http://forums.pelicanparts.com/uploa...1322052132.jpg

http://forums.pelicanparts.com/uploa...1322052144.jpg

When I first began having intermittent problems with the "start" position on the ignition switch, I installed a push button start switch--a simple button bought at Kragen. I mounted it in a hidden location that was easy to find by "feel"; underneath the dash, where the three "plugs" for the wiring harnesses go through the bulkhead into the trunk, behind the light switch. There is an open area in the sheet metal to drill the hole and the access to wiring is in the trunk. Simply ran a switched hot from the fuse block to one terminal of the button and a yellow jumper to the yellow wire for the starter solenoid to the other terminal. No one can see the button without looking upside down under the dash, yet you can easily find it by reaching your hand under, finding the plugs and moving a bit to the left. If you need it on a regular basis, finding it will be even easier.