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Old 12-05-2003, 11:21 AM
vangos vangos is offline
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light stalk rebuild

Ever since I bought my 73 gtv, the light stalk needs some jiggling in order for the headlights to come on and stay on (after the stalk is turned to the right position). Has anybody successfully rebuilt one of these? I have heard that the rivets holding the plastic casing together can be drilled out and later replaced by bolts. Any advice?

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Old 12-13-2003, 08:11 PM
vangos vangos is offline
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Well it so happened that a similar question appeared in the alfa-digest and a couple of people posted solutions for fixing the switch. I followed Rex Chalmer's advice on cleaning the switch contacts and it worked like a charm:

After removing the cowling (I had to pull the steering wheel to slide the top half off), there's easy access to the contacts that close the circuit which operates the lights. The low and medium beam contacts are at the top rear of the switch and the high beams at the bottom. I took a narrow piece of very fine sand paper, folded it in half and slid it between the contact points. I then used the switch to close the contacts and gently pulled the sand paper out. I repeated this a few times, sprayed the contacts with some contact cleaner to make sure they are really nice and clean and put everything back together.

All in all the process took about half an hour and all the lights work great now.

Vangelis
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Old 12-14-2003, 09:53 AM
ossodiseppia ossodiseppia is offline
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That's the perfect way to clean the contacts. You may have something really wrong with your switch. If you have to giggle it, it's possible there's more damage. Clean the contacts as described. If that doesn't resolve the issue, you'll need to remove the switch and cut it open. The rotating switch that turns the lights on has a plastic or nylon cam. As the switch is turned, the lobe is brought up to push the contacts together. The lobe actually turns on the parking lights and the headlights. I've seen a switch where the lobe that actuates the headlight switch was melted. The contacts looked good, so, I thought I could try and repair the lobe. You may be able to put a dollup of epoxy or JB weld and reshape the lobe. It may be better to put a small screw in the lobe and then a dollup on top. The screw may act as a better anchor than the nylon itself.

Putting the switch back together is a snap. Go to the hardware store and buy some brass tubing of the correct diameter (take the old rivet with you) to use to make some rivets. One thing to remember is the location of the aluminum washer. It's on the top of the switch and not on the base. If you reassemble the switch and put the washer on the base, the cowel may not fit back on. Cut a piece of the brass tubing a little longer than the depth of the hole on the switch plus the washer where the rivet goes. It should be no longer than about 2 mm on either side. Get two flathead screws. These are the kind with the beveled head. It doesn't matter if they are machine or sheet metal screws. Cut all but a few mm of the threaded portion off. Put the cut piece of tubing in the hole, with the aluminum washer in the right place and put a screw in each side of the tubing. Make sure the threads are in the soon to be rivet. Carefully place the assembly in the jaws of a vise. Make sure to align everything so that the same amount of the brass tuning is sticking out of either side. Slowly put close down the jaws so that the squeeze the screws into the tubing. This will roll the edges of the tuning. DO NOT TIGHTEN THE VISE TOO MUCH OR YOU WILL CRACK THE SWITCH. Once the edges are rolled over and the two halves of the switch are held firmly together, remove the assembly and the two screws. Put the switch back in the vise so that the rolled over edges can be further rolled over until they are flat. If you have the right length of tubing, it will not crack and split when it's rolled flat. If it does split, it's probably ok, as long as it will hold the two halves together.

BTW, it the cam lobe is melted, you may wish to consider adding relays to your car. This will take the load off the switch.

If the contacts are bad, take try and find someone in your area that can put in new contacts.
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