Hazard switch for 911 of 1966

[EdHut]

Hi all,

The hazard (or warning or emergency) lights of the 1966 911 I bought a few months ago have never been working and now I want to fix them.

To my surprize the wiring diagram of 1965- does not mention the hazard lights at all, so I'm relying on later diagrams.

Also, the switch has part number 901.613.623.01, while the part number listed on th online catalog of Pelican Parts is 901.613.623.02 (only last digit different). From the picture that's in the catalog I can see that the connections of the latter are different from the one I have (which has four).

Finally, the 'blink light unit' (Hella) has only three connections, which is how it's shown in the 1965- diagram.

My questions:
1) I plan on buying a new switch, because the knob of mine is broken. Can I buy the "02" one, or should I start looking for a "01"?
2) how to wire the whole thing up?

Any advice greatly appreciated.

Ed

[This message has been edited by EdHut (edited 07-04-2001).]

[Roland Kunz]

Hello

Well this is a very complicatet theme. The hazard switch was not stock in every country and some parts are NLA.

Right now I need to know what version you have ( USA, Germany, Swiss, France, Austria ).

Also where is the switch placed ? Abouve the radio or beside the light switch ? What is your knob design ? Like the other switchs with a small dot or a big pull switch with complete red surface lighting up ?
What is your exact Modelyear ( 65,66,67 ).

Witch Blinker relay is in the car a big round can unit or a small round can unit or a later plastic case cube ?

Maybe Warren was faster......

Grüsse

[EdHut]

OK, here goes...

My car is a USA version.

The switch is placed above the radio and is like the other switches, i.e. it has a small dot in the middle.

The modelyear is 1967, although the car is build in 1966 and has several 'pre 1967' characteristics like the locks that still have the same small keys as the 356's and early 911's. (BTW the chassisnumber is 305211)

The blinker relay:
- brand: Hella (with markings 91PSFT 2x32Cp 12V)
- height: 45mm
- diameter: 30mm
On the base it has the following markings next to the contact points:
- 54L 49a
- KPC
- 15x49

Hope this helps.

Ed

[This message has been edited by EdHut (edited 07-05-2001).]

[Roland Kunz]

Hello

OK looks like original early setup so this is very straight forward as long you not need relays.

Wire shematic : http://www.pelicanparts.com/911/911_Parts/Electrical/911_electrical_1965.jpg

1.) You just need to buy the knob
2.) The whole thing is allready wired up follow the shematic and you will find out everything. The additional relays are abouve the pedals. Shorting the switch should run the emergency flasher. Check the inline fuse ( 57 ) in the green/white power suppley to the emergency flasher unit ( 45 ( power relay ) & 46 ( flasher relay )).

AHHH The hazard function is named control.

Maybe that confuses you. Sorry I seldom read the Key/legend as I know the colors and pins.

Grüsse

[EdHut]

Thanks Roland, your reply makes it a bit easier to try to make things work. The previous owner obviously had some of the wiring replaced (or added later) without using the proper colouring for the wires. It makes it quite difficult to follow the wires.

Sorry to bother, but when I buy the new hazard switch, should I stick to the original partnumber 901.613.623.01, or can I also use the "02" one?

With "the additional relays are above the pedals", you mean they are in the driver compartment and not the trunk? (I really like it down there, makes me wish I was not so tall....)

Cheers,
Ed

[Roland Kunz]

Hello

I think the 02 is a other switchtype. Now is there any need for the switch ? It is just a simple switch not very mystice.

Yes some relays are abouve the pedals behind the board.

Just try to find out your problem and then get the parts.

Grüsse

[EdHut]

Roland,

Yes, there is a need to replace the switch, because the thread on which the knob is fastened has broken of. The previous owner has tried to fix it using superglue or something like that, but it does not hold (the knob felt off while driving over some bumps...).

I've also started tracing the wires and there is for sure a short somewhere. The inline fuse (57) was blown and a replacement blew as expected. Looks like I have to crawl behind the pedals to trace the wiring.

Ed

[EdHut]

Well, after some cramped testing behind the pedals, I finally found the cause of the error. It appears that the so called 'control light unit' has shorted out in a way that causes the power line to get in contact with the aluminium cylinder. Since it's attached to the bodywork with a rather weird clip, this means you've got a short!
When I detached it from the bodywork, the unit was actually working sometimes, depending on how I was holding it (upside down, 90 degrees to the right, ...)

So it looks like a trip the my local store...

BTW: the unit has '6-66' stamped on it, so this not only makes it a very old unit but also a vey EVIL one!

[This message has been edited by EdHut (edited 07-08-2001).]

[Roland Kunz]

Hello

Well I thought that Bill Gates is evil. 6-66 staates the production date this part is just short over 35 years. A "average" american renewes his car in 2-3 years to avoid such problems.

Well lets see if your local store can give you a correct item.

So the switch is working despite the brocken pull rod ?

Grüsse

[EdHut]

The switch itself is working, but the thread onto which the knob is fastened has completely broken of. The only way of operating the switch now is by using a tool to pull it out. Glueing has not worked so far, so i'm looking for a new or used one.

Thanks for your help Roland. I noticed you live in Stuttgart. Any connection to the Porsche factory?

Ed

[Roland Kunz]

Hello

I think the old fog light switch is similar, only difference is the lens in the knob.

You have the chrome bezels ?; they have small holes to unscrew.

Connection to Porsche AG ? sure I pick the phone and dial 911 0.

If I would be a Porsche employe I would get some restrictions not to interfere or hurt the Porsche dealers area. If you are a normal customer and call Porsche for technical support they send you to the next dealer. Now imagen you had brought your car to the next dealer. They would sure have done the job and most of them work better then the "average" mechanic. But you would miss that special satisfying "I made it".
And not to forget you heve full control about the investet money to quality relation.

On the other side your local Porsche dealer lost a chance to win a new costumer for a long relationship to make money.

See when I startet working on Porsches I had many costumers who couldn´t afford ther 914 or 924 repaired at the dealer some of them couldn´t afford the car anyhow. It was just there dream to drive a Porsche. Now some of those first costumers run companys and earn fat money. The funny thing is they still stick to old realtionships. F.E I have a costumer who runed a old worn out 911T as a studend and he never had enough money to fix his car. Made every shortcut to save money. Some years later he had enough money to make the car into a very good condition. For the same moeny he could also go to Porsche and say: One 911 Coupe full loaded please ( BTW he bought a new 993 RS and leased a 993TT for daily transportation ).

Grüsse

[EdHut]

Well, I tried to buy a replacement part from a car parts shop, but no luck. It appears this is a rather curious part. In effect it's a blinker relay that has separate connections for the left and right side of the car. So then I tried the local Porsche dealer only to find out that the part in question is no longer available. They adviced me to upgrade the blinker system to the configuration that was introduced in 1969 (turn signal and hazard light combined in one unit). Since that involves some rewiring and also replacement of the hazard switch itself this would cost me at least a hundred bucks.

So then I thought, what the heck, lets open this defective relay and try to find out what's causing the problem. Well, lucky for me only a small nipple that limits the movement of the actual relay switch was broken off. I managed to repair it using a paperclip (!). The relay makes a horrible noise now, but who cares? If I'm lucky I don't need to use the hazard lights ever.

BTW: just for the fun of it, I'm considering to build the blinker relay myself. I'm no electronics expert at all, but I found out (on the web) that the blinking light circuit is about the first lesson in electronics courses. How difficult can it be then?

Ed

[Roland Kunz]

Hello

Didn´t I say some parts are NLA ?

The original units are a bit loud too.

Well I replace the original unit by a small deduco realy and some one way diodes. They will fit in the housing.

Yes do some base electrics like time delay or voltage regulator smal amplifier.

Its some kind of entertaining and you willl find many usages. But today everything is SMD and integratet so you can´t use that knowledge direct for you VCR repair.

Browse the net there are some interessting sites out there.

Grüsse