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Posted by: bluhun Aug 5 2010, 05:27 PM

My original headlight switch began malfunctioning when the beams failed to come on when the headlights popped up, unless the switch was pushed forward a hair.

The switch was replaced with a used one, which operated for a year or so when it began to malfunction in the same manner.

The switch was opened and the worn contacts were resoldered, which cured the problem for a few months before the switch started failing again.

The new switches are no longer available, as far as I can tell, not even from Automobile Atlanta.

Does anyone have a permanent fix for this problem?

Posted by: ripper911 Aug 5 2010, 05:29 PM

Buy a lot of used ones, you'll need them.

Posted by: bandjoey Aug 5 2010, 07:47 PM

I'll look for a link later but I've seen an old post of modifying a vw switch that's available and cheap.

Posted by: kg6dxn Aug 5 2010, 10:26 PM

If you keep burning out switches, install relays to carry the load instead of the switch. Use the switch to activate the relay.

Posted by: Lennies914 Aug 5 2010, 10:41 PM

QUOTE(kg6dxn @ Aug 5 2010, 09:26 PM)

Posted by: realred914 Aug 6 2010, 09:14 AM

yes, realys!!!! that will give you brighter lights and save the switches life. when you run a relay, teh switch will last much much longer. besure to sue contact lube when you rebuild your switch. but for sure, add a set of relays to reduce the load on the switch. you will really like the brighter lights a hole lot!!!! honest!!!!


have fun

Posted by: bluhun Aug 6 2010, 01:37 PM

QUOTE(realred914 @ Aug 6 2010, 08:14 AM)

Posted by: 914Sixer Aug 6 2010, 02:49 PM

Switches do not burn up unless they are being overloaded. Are you burning up fuses? The lights all have fuses on the fuse panel.

Posted by: bandjoey Aug 6 2010, 05:37 PM

My switch didn't burn up, and doing a light switch search, found a lot of switches just break up inside. The detent springs on mine broke, and the crud caused the insides to slowly grind away until it was no good. Turn it upside down, and look at the chunks of bakelite and springs fall out.


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Posted by: bandjoey Aug 6 2010, 07:04 PM

Here's the only link I could find on a vw replacement part. Not a lot of description but tells us what needs to be done. A good electrical mechanic should set up an adaptor from the old wires to the new plug . With the cheaper part, it'd probably sell.

http://www.914world.com/bbs2/index.php?showtopic=45370&st=0

Posted by: Marlow Aug 7 2010, 09:04 AM

This might help for the VW switches. Output diagrams of a bunch of different VW headlight switches.

http://www.oldvolkshome.com/headlight_switch_OVH.pdf