Have you ever wondered what the inside of the ignition switch is like. Maybe it is just me, but I have and so I decided to take one apart.
After testing the switch for resistance and finding resistance in excess of 1.8 Ohm, it was obvious there was an issue. High resistance creates heat. Heat melts wires. Melted wires can cause running problems and possibly fire. Can't count how many melted ignition switch wires I have seen, it's been many.
The first picture is just that of the back side of the switch. The trick is to get the switch open with out breaking the plastic or the cast body.
I found that I can tap the three swaged spots open by gently tapping those areas with a small chisel or punch with a hammer. Once these are opened up enough , the plastic part with the terminals can be removed.
Picture two shows the two separated. Not really much to an ignition switch is there? I cleaned all the contact surfaces with a wire brush in my Dremel tool.
The two switches I did both had a burned surface for the Accessory position. The burned spot had a rough point. So, I gently filed it , then polished with fine wet dry sand paper. Then lubed all contact points with a special Lubriplate for electrical switches, reassembled the switch and retested.
I now had 4 tenths resistance through all points, which is good. This switch is now good as new.
Loren
