Date: Wed, 30 Mar 2022 00:23:31 +0000
Reply-To: Richard Koerner <rjkinpb@SBCGLOBAL.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Richard Koerner <rjkinpb@SBCGLOBAL.NET>
Subject: Re: Manual Tranny, funky Reverse Light Switch
In-Reply-To: <CAFnDXk0pop9QWcmaa_1eZq3gvGSD6tFNRDVa_-GucLStSwWu+A@mail.gmail.com>
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I am assuming the switch installed was my old one. But like I say, if you move the plunger on that switch only .025 - .035, that's enough to trigger the switch. Meanwhile, the total plunger travel available is more like .200". If I were designing it, I would put the contact point about a third to midway of available travel. Like most plunger switches. Gives enough latitude for tolerances. I suppose for the fun of it I could keep experimenting with adding shim washers until it's "just right" in all 4 gears + Reverse.
On Tuesday, March 29, 2022, 04:43:26 PM PDT, Jim. Felder <jim.felder@gmail.com> wrote:
Is it the same switch or a new switch? Apparently there were a lot of
variety among Vanagon switches, and sometimes shops do not get it right. It
pays to check that carefully.
Jim
On Tue, Mar 29, 2022 at 5:34 PM Richard Koerner <rjkinpb@sbcglobal.net>
wrote:
> On my 4 speed '85 Vanagon, I recently had the transmission rebuilt; the
> way we did this was NOT to use my existing transmission; instead, my
> mechanic had a transmission rebuilt from some other guy's Vanagon. This
> allowed us to do a one-day exchange....old transmission out, fresh
> transmission in, and my old transmission will be used by next customer. My
> mechanic has done this numerous times; the local re-builder he uses has an
> excellent track record.
>
> The problem is the Reverse Light Switch. It has a "hair
> trigger"...meaning, you barely touch the plunger and the reverse lights
> activate. I have tried numerous iterations of washers & thin shims to
> solve the problem; I am assuming my switch is my original one, transferred
> over. At first, I thought I had it solved with the proper combination of
> shims to move switch away from transmission a tiny bit, but the problem is
> back. Reverse lights come on in all gears. If I totally remove the switch
> from tranny but still electrically hooked up, it's fine; but the moment I
> barely touch the plunger of the switch, lights come on. Seems way too
> sensitive.
>
> I am suspecting a bad switch. Something funky happening internally.
> Wondering if you guys have any experience with this issue?
>
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