If you search the forum...there are instructions on how to re-build the headlight switch....with pictures....but because the thread is so old, the pictures dont appear....

Does anyone have UPDATED instructions WITH the pic's on how to re-build the headlight switches....

 

What year do you have, and what specifically about your switch doesn't work?

 

'89 T2...
dash and tail lights didnt work...replaced switch everything fine....

idling in driveway the other night.....dash lights went out...no tail lights again.....checked fuse....

checked forum....did search...lots of threads indicated this was the light switch...then found thread on how to re-build but because the thread is so old....none of the attached pictures showed....

 

Usually when the switch is replaced you also replace the wiring harness because one can take out the other which sounds like what happened in your case.

 

start by desoldering these pins then wiggle the main board off the assembly. also remove the 2 screws on either side of the header junction connector holding the board to the case.

 

pry at tabs 1-5 alternating and wiggling the socket board loose from the housing and pull it out carefully. remove the springs and the headlight retractor wiper switch from inside and set them aside.

desolder 6

mark 12 with a felt pen on one of the plastic lock tabs in a location you plan to line up later
remove bulb near 7 and pry lightly on the dimmer board so that it pops up slightly
alternately pry with a small pick tool at 8 and 9 to get the board from under the tabs, be careful not to break the dimmer board!
once loose at 8/9 then pry at 10 and 11 while tilting the board fore and aft until the whole board is loose then lift it out of the housing


no pictures beyond this point, but i leave the dimmer switch **** in the white plastic housing, pry at tabs 7, 8 and 9 until you can lift the white housing out of the cavity, beyond that you will see the actual headlight rotary switch contacts.

clean everything, note any damaged traces on the board, burnt header pins, etc etc that need addressing prior to reassembly.



the pictures may make it look easy, this however is not a novice job and you may wind up destroying your switch without one to practice on first.

 

the switch also isn't always the culprit, but merely the weak link in the system. check and clean all grounds for the headlights and parking light circuits to prevent recurring failures.

converting at least part of the exterior lights to LED will also take a bit of load off the switch. hmmm, just gave myself another idea to put together a full LED FC bulb kit to alleviate this issue.

 

Thanks for the pics and info RotaryEvolution....

will check connections and harness this time....

 

RotaryEvolution - your comment about not being an easy job...I have 3 switches that dont work...so......hopefully one to practise on ...one for the car and a spare...

thanks again for all the info

 

This might be a long shot, but does anyone have the pictures saved for this?? I'm in a bad spot and need to rebuild my switch.

 

Bump it up

 

Can we get n update post on these pictures, trying to get into mine instead of spending 650aud on a new one

 

Check with these guys :

https://www.geespecautomotive.com/pr...repair-service