Another reverse switch issue - mechanical problem?

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StuY
Posts: 20
Joined: 15 May 2015, 20:08

Another reverse switch issue - mechanical problem?

Post by StuY »

The reversing lights on my 206SW (2004) were not working, and I traced the fault to the switch (so I thought). If I unplugged the connector from the switch and shorted out the contacts, the lights come on. I removed the old switch, with some difficulty as the head sheared off while I was unscrewing it. I have tried two replacement switches of different makes, one from ebay (unknown source, brass body), one from eurocarparts (made by FAE, steel body). Both put the lights on when plugged in and the switch button is pressed manually, even a tiny amount. Neither work with the switch fitted to the gearbox. I have tried turning a little bit of material off the mating face of one of the switches, which has given an extra half turn (~0.75mm) penetration into the gearbox, but still no joy. There is no washer or seal between the switch body and the gearbox boss. I'm beginning to suspect that the old switch had been machined even more aggressively, which is why the brass body came apart when I removed it - the shell seemed to be paper thin at the mating face.

I'm totally stumped now - has anyone come across a similar problem? Any ideas? Is it normal for wear in the gearbox to affect the switch operation? I can see the tab coming into position below the switch socket as it goes into reverse, but it just doesn't seem to be hitting the switch...
StuY
Posts: 20
Joined: 15 May 2015, 20:08

Re: Another reverse switch issue - mechanical problem?

Post by StuY »

Just tried machining it down further and it sheared off exactly the same as the other one while putting it in...
speedy3
Posts: 17
Joined: 02 Jul 2015, 20:23

Re: Another reverse switch issue - mechanical problem?

Post by speedy3 »

hi StuY I used to recon gearboxes and a common fault with pug boxes is the reverse post inside the box used to wear so it
push the switch pin enough to put the reverse lights on
StuY
Posts: 20
Joined: 15 May 2015, 20:08

Re: Another reverse switch issue - mechanical problem?

Post by StuY »

Ok, thanks Speedy! No obvious visible wear on the surface that I can see through the hole, but I think that must be what is going on. Think I'll need to bodge something up as I don't want to be digging inside the gearbox...
StuY
Posts: 20
Joined: 15 May 2015, 20:08

Re: Another reverse switch issue - mechanical problem?

Post by StuY »

I fixed this by making an M14x1.5 to M10 adapter out of the barrel of one of the broken switches. I got a Febi 02778 switch off ebay, which is a longer M12x1.5 switch with plain spade connectors. I skimmed the new switch down from M12x1.5 to 10mm dia and cut a new M10 thread on it, which worked ok. Afterwards it was still stronger than the one that was in there originally anyway... I put a bunch of washers between the switch and the gearbox boss (with the adapter screwed into it) and took them out one by one until the reverse lights worked. Bit of a faff, but quite neat and all reversible just by re-splicing the old connector onto the loom if I ever change the gearbox.

I suppose the big question is: how knacked is the gearbox when the reverse lights stop working?? :? :)
elma
Posts: 3745
Joined: 13 May 2007, 02:17
x 287

Re: Another reverse switch issue - mechanical problem?

Post by elma »

StuY wrote:
I suppose the big question is: how knacked is the gearbox when the reverse lights stop working?? :? :)
Good fix, I really wasn't sure what you could do about that.
I suppose if your gearbox sounds and feels alright and is on fresh oil it's ok, hopefully.