Date:         Wed, 24 Feb 1999 21:44:56 EST
Reply-To:     SBate82659@AOL.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Sam Bateman <SBate82659@AOL.COM>
Subject:      Re: Headlight switch failure
Comments: cc: tonyd@CANDESA.COM
Content-type: text/plain; charset=US-ASCII

In a message dated 99-02-24 14:31:04 EST, you write:

<< Driving back from California a week ago my
 headlight switch siezed. I turned the headlights
 off (parking lights still on) and when I went to
 turn them back on, the switch would not move! It
 was stuck! I took the dash apart and took out
 the switch, but there doesn't seem to be any way
 inside. I ended up driving by holding on the
 brights until dawn, and buying a used unit at
 the yard for $5 (bargain) when I got home.

 Has anyone had this happen to them or no the
 cause and/or repair??

 any input would be appreciated.

 Tony >>

Oh yeah........had almost the exact same thing happen on my '87 GL except the
switch siezed in the "on" position.
When I arrived home at 11:45 P.M. and went to turn the lights off it wouldn't
move!
There is a way inside the switch because I dissassembled mine and 'carved' the
melted plastic out of the contact area and reassembled it.
Be carefull when popping the housing open - there will be a tiny ball just
aching to escape and roll across the floor under something where it can't be
retrieved.
While you're in there, be sure to clean-up the contact surfaces with emory
cloth or a very fine file.
It takes a bit of patience to put the whole thing back together especially
that *^%%$ ball that causes the switch to 'click' into the parking and main
light positions.
I found a bit of grease (a TINY bit) on the ball made it stay in place until I
could get the rest of the housing together.

Hope this helps,

Sam Bateman
Fork Union, VA
'87 Vanagon GL
'85 Audi 5000S Avant