Restoring 68-76 XS Door Switches Simple how to.

[Rich P.]

If ya'll don't mind I figured I'd post a few pictures of the restoration process of a set of 68-76 door a-jar and courtesy light switches.

First the long switches are the courtesy light switches. And the short ones are the a-jar switches.

It is a very simple process. First you remove the plastic wire terminal plug. This is done by grabbing the plug and pulling it off, this will require a deacent amount of force as the plunger is barbed at the end.

The light switches have 4 parts that disassemble. 1 the plug 2 the pin/plunger 3 the spring and 4 the housing.

The a-jar switches have 5 parts that disassemble they are the same as the light switch with the exception of the spring retaining tube.

Once they are disassembled you can then clean and replate them (cad/zinc).

[Rich P.]

Re: Restoring 68-76 XS Door Switches Simple how to.

Next is the assembly which is also simple. First you might need to remove terminals in the plug and to do so you need to use a small flat blade screw driver or something similar and pry from the top of the plug on the outside of the terminal and the inside of the outer wall of the plug. What you are doing is pushing the terminal tang back into the opening to allow removal of the wire/terminal from the bottom.

[Rich P.]

Re: Restoring 68-76 XS Door Switches Simple how to.

While assembeling the switches dont mix up the springs as they are desigend for the 2 different length plungers. Also as you assemble the a-jar switches you need to make sure the spring retainer tube slides in and out freely with the plunger otherwise they won't work properly.

The light switch plunger/pin only moves about an 1/8"

[Rich P.]

Re: Restoring 68-76 XS Door Switches Simple how to.

Once you know the switches work properly you can put the terminal plugs back on. To do this place the head of the pin/plunger on a flat firm surface and use something with a hole in the center that will still make contact with the flat of the plunger and press on. I happend to have a 63-67 hardtop sidee bolt/nut assembly handy and it worked fine. You want to make sure the plug is set securely and wont loosen up and let the pin go flying.

Rich

[Rich G.]

Re: Restoring 68-76 XS Door Switches Simple how to.

Rich

Thanks. Very timely. My 68 courtesy light switch is starting to get flakey.

Rich G

[Ken C.]

Re: Restoring 68-76 XS Door Switches Simple how to.

nice article rich.since my spring retaining tube is fused to the housing. I'm in the process of taking the plunger with the SX and installing it into new GM housing. I was able to salvage 1 of the housings but the other is shot.

[Terry M.]

Re: Restoring 68-76 XS Door Switches Simple how to.

Rich,
I would wager Vinnie would like this info for an article in The Restorer. I think it would have interest beyond this board. Please consider sending it to Vinnie.

[Rich P.]

Re: Restoring 68-76 XS Door Switches Simple how to.

nice article rich.since my spring retaining tube is fused to the housing. I'm in the process of taking the plunger with the SX and installing it into new GM housing. I was able to salvage 1 of the housings but the other is shot.

Ken,

good move. I have done this in the past. Just watch some of the later housings have a machined look to them. If yours does I would suggest lightly sanding all the flats with a disc to remove the macine marks, then either blast or wire wheel the housing to remove machining marks then plate. You have to plate the XS plungers anyhow.

[Rich P.]

Re: Restoring 68-76 XS Door Switches Simple how to.

Rich,
I would wager Vinnie would like this info for an article in The Restorer. I think it would have interest beyond this board. Please consider sending it to Vinnie.

Terry,

already in the works Reba got the ball rolling and then Vinnie contacted me. I will add more pictures along with a better detailed wording and add in Kens housing swap also.

Rich

[Terry M.]

Re: Restoring 68-76 XS Door Switches Simple how to.

Good news. Thanks.

[Edward J.]

Re: Restoring 68-76 XS Door Switches Simple how to.

To add to Richs article, I had one of the tubes bent on one of my SX switchs for the door ajar, I Took one of the repro switchs apart and used the tube from it and re- assy'd as rich has done and it works great.

For those of you who have tryed the reproduction switchs they rarely work properly, but they can be used for spare parts as I did.

[Ken C.]

Re: Restoring 68-76 XS Door Switches Simple how to.

To add to Richs article, I had one of the tubes bent on one of my SX switchs for the door ajar, I Took one of the repro switchs apart and used the tube from it and re- assy'd as rich has done and it works great.

For those of you who have tryed the reproduction switchs they rarely work properly, but they can be used for spare parts as I did.

Ed, doing the same at this moment to mine. Looks great Add some super glue to where the plastic piece goes to plunger, just in case the burr's done hold correct.

[Alan S.]

Re: Restoring 68-76 XS Door Switches Simple how to.

Hi Rich,
Very informative pictures and description.
You may want to add that the terminals are available (in sets of 5 or six, if I remember) from various venders. I needed one because I broke one of the terminal tangs off getting it out.
NICE WORK!
Regards,
Alan