Headlight Switch Sticking

G

G_Don

Member
Hi All,

I just put a new headlight wiring harness in. No problems with the install except it does not seem to operate smoothly. The switch is difficult to turn, almost to the point where it feels like I have to force it.

Wondering if I am supposed to apply any type of grease or dielectric grease to it to get it to operate more smoothly?

Thanks in advance for your time!
Gordon
 
Hi Gordon, the bakelite portion of the new harness is probably a "thicker" diameter than the original. I've had to file down the outside lip in the past so the harness doesn't press so hard on the switch portion.
The thickness difference could the thickness of a dime to the thickness of a quarter. Hope this helps.
Don't file the outside diameter.
If I recall I filed the back side. Where the wires attach. Jeff
 
I think Jeff is right, as the repro I installed for a customer about 10 years ago was very stiff to turn.
I sanded each divot to round over the edge, and that helped. I also applied grease to the divots.
 
I had the same problem with mine. I bought the US made wiring harness from Berts and the US made light switch from Brattons. Steve at Berts put one together and found a solution. He carefully belt sanded about 3/32 from the lower part of the switch. I put the harness in the bottom, assembled the top (out of the car). Inserted the spider and tried to move it with a 1/4" drive ratchet. I kept sanding more off until it worked smoothly. It took a while, but after 2 weeks of fighting it, including shearing the ears of the spider, I HAVE LIGHTS!
 
Much easier to sand just a bit off the lower metal piece lip, then sanding the black disk or each divot.
 
A new headlight switch will be difficult to operate until it accumulates some wear on the contacts. NOS original light switches exhibit harsh operation as well until they wear some. Use the dielectric grease.

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As part of my solution I carefully milled the plastic contact holder thickness from the oversize .335 to the spec .310 and filed all the contacts flush to the plastic surface. If you view the photo closely you can see the difference in the size of the contacts after filing.
 

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I ended up using the dielectric grease and it feels a great deal better. Still a little tight but I'm hoping itll just break in over time. I was nervous to shorten the contact housing however over time, if it doesnt break in, I'll be sure to try something different!

Thanks for all the replies! I really appreciate it!
Gordon
 
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