Ignition Switch Repair, Porsche 911

[Determined]

I figured out a way repair the common break point on our Porsche 911 ignition modules. I have a few of these broken and I was bored Saturday so I tried an idea that actually worked. Pictures are self-explanatory but in summary I did as follows:

1. Ground down broken stub to be flat as shown in the picture.
2. I used a simple flat-end threaded screw and ground it to the shape as shown in the picture so that it fit all the way in the switch and was snug. There is normal flex in the switch and module so it doesn't have to be perfect. I got lucky and it was a near perfect fit.
3. I drilled out a whole in the ignition switch module and was careful to remove the material. I don't recall how deep I want but it was enough to thread it well into the piece.
4. Thread the hole then carefully remove the burrs. I used a small amount of locktite on the screw threads to secure it. Be sure to properly orient the new stub relative to the switch, there is a guide on the switch and module for proper alignment.
5. Assemble and Test, worked fine. I think this is much stronger than the factory piece that breaks on occasion.

Over all, about 30-minutes of work and total 1-hour to complete. It was fun...now I'll fix my other one and keep them as spares. Sorry guys but the pictures are out of order, I think you get the idea.

[boyt911sc]

You are a genius! I wanted to fix a couple of broken ignition switches like yours and could not figure out a good way to restore them. I was thinking of a good way to create the nub to drive the electrical tumbler and came up short. I put my hat off and bow my head to your incredible fabrication. Thanks.

Tony

[Determined]

You're much too kind, it was fun and pretty quick. I’ve done write ups in the past including in the Cayenne forum but it’s been a while. Glad you liked it, these ignition modules are expensive.

Best Regards,
Alex

[93nav]

I do not understand if you threaded in the modified screw from the bottom or top. I would think the top, but the pic implies otherwise.

Thanks

Great solution.

Originally Posted by Determined

I figured out a way repair the common break point on our Porsche 911 ignition modules. I have a few of these broken and I was bored Saturday so I tried an idea that actually worked. Pictures are self-explanatory but in summary I did as follows:

1. Ground down broken stub to be flat as shown in the picture.
2. I used a simple flat-end threaded screw and ground it to the shape as shown in the picture so that it fit all the way in the switch and was snug. There is normal flex in the switch and module so it doesn't have to be perfect. I got lucky and it was a near perfect fit.
3. I drilled out a whole in the ignition switch module and was careful to remove the material. I don't recall how deep I want but it was enough to thread it well into the piece.
4. Thread the hole then carefully remove the burrs. I used a small amount of locktite on the screw threads to secure it. Be sure to properly orient the new stub relative to the switch, there is a guide on the switch and module for proper alignment.
5. Assemble and Test, worked fine. I think this is much stronger than the factory piece that breaks on occasion.

Over all, about 30-minutes of work and total 1-hour to complete. It was fun...now I'll fix my other one and keep them as spares. Sorry guys but the pictures are out of order, I think you get the idea.

[Determined]

I threaded into the main module top not the round switch. I only ground the head of the screw to fit the profile of the round switch in which it just slipped in.

[Determined]

I believe I also did a post on how to re-key the ignition or just restore your ignition module so your key works better. The brass tumblers wear over time and cause problems with the key, it’s an easy fix and new brass tumblers can be bought on ebay if needed.

[boyt911sc]

Alex,

Where did you buy the thumb screw you used for the repair? Do you remember what size is the threaded section? 3/16” or 1/4”? Thanks.

Tony

[Determined]

Ace hardware, I’m traveling overseas at the moment so I’ll check when I return.

[PorterF]

It works! I used this method to successfully repair my broken switch interface last weekend.

I was able to drill 1/2" down from the surface and use a #10-24 threaded tap.

Helps if you have a bottoming tap. You can also buy "thumb screws" that are this exact size and dimension. I ended up making my own out of another tabbed type screw. Used the red formula thread locker.

[Determined]

Good job! I’m glad it worked for you, saves slot of money and it’s probably stronger now as well. Alex

[Kraftwerk]

Nice fix.