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Date:         Tue, 29 Mar 2022 22:34:11 +0000
Reply-To:     Richard Koerner <rjkinpb@SBCGLOBAL.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Richard Koerner <rjkinpb@SBCGLOBAL.NET>
Subject:      Manual Tranny, funky Reverse Light Switch
Content-Type: text/plain; charset=UTF-8


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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