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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
Comments: To: "Jim. Felder" <jim.felder@GMAIL.COM>
In-Reply-To:  <CAFnDXk0pop9QWcmaa_1eZq3gvGSD6tFNRDVa_-GucLStSwWu+A@mail.gmail.com>
Content-Type: text/plain; charset=UTF-8

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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