1957 Headlight Switch & Circuit Breaker Assembly - Reinstall problem with shaft

TbirdFan76 · Tuesday at 7:38 PM

I removed the Headlight Switch assembly while trouble shooting an issue with parking lights and turn signals. See https://forums.fordthunderbirdforum...n-signal-on-when-parking-lights-are-on.16822/

When reinstalling the the shaft & knob for the for the parking and headlights it locks in as it should. However then it won't pull out at all to turn on the parking or headlights. It does rotate left and right as it should. I've tried lubrication and turning it slowly while inserting it in hopes it will catch the lock correctly and allow it to function but so far luck.

If you've encountered & resolved this issue or just have some ideas to try please let me know.

Thanks.

cokefirst · 2025-05-28T00:21:40-0400

Welcome to the world of "exact reproduction" parts. Yes, I had the same problem. We spent a day trying to massage the part to get it to fit. You probably found that it will engage the shaft if you remove the bezels. It has been a few months, but we could not get the system to work. Are you using a reproduction knob and shaft? did you replace the bezels and knob for the dash dimmer. Let me know as I don't remember the exact cause, but the information you give me about what you have changed may jog my memory. In the end, I would up cleaning the original switch and replaced the rheostat for the dash light dimmer.

TbirdFan76 · 2025-05-28T01:32:09-0400

cokefirst said:
Welcome to the world of "exact reproduction" parts. Yes, I had the same problem. We spent a day trying to massage the part to get it to fit. You probably found that it will engage the shaft if you remove the bezels. It has been a few months, but we could not get the system to work. Are you using a reproduction knob and shaft? did you replace the bezels and knob for the dash dimmer. Let me know as I don't remember the exact cause, but the information you give me about what you have changed may jog my memory. In the end, I would up cleaning the original switch and replaced the rheostat for the dash light dimmer.

I'm working with the original switch. It has the Ford oval embossed on the metal back. I took it out to clean it and then reinstalled it.

I did lubricate the release button with WD40 and pressed and released it several times to work it in. I've also lubricated the shaft with lithium grease hoping that might help.

I've released and reinserted the shaft several times using slightly different technics turning the shaft slowly to see if that might help it engage the lock correctly. No luck yet.

Is there a way to release the metal back from the plastic with the various electrical tabs to check the release button isn’t stuck?

Tom Alpers · 2025-05-28T02:51:01-0400

TbirdFan76 said:
I'm working with the original switch. It has the Ford oval embossed on the metal back. I took it out to clean it and then reinstalled it.

I did lubricate the release button with WD40 and pressed and released it several times to work it in. I've also lubricated the shaft with lithium grease hoping that might help.

I've released and reinserted the shaft several times using slightly different technics turning the shaft slowly to see if that might help it engage the lock correctly. No luck yet.

Is there a way to release the metal back from the plastic with the various electrical tabs to check the release button isn’t stuck?

When you put the shaft in it are you holding the "release" button down? If not, try holding the release button down while putting it in. When its in, release the button and try it.

TbirdFan76 · 2025-05-28T09:12:38-0400

Tom Alpers said:
When you put the shaft in it are you holding the "release" button down? If not, try holding the release button down while putting it in. When its in, release the button and try it.

I'll give that a try.

TbirdFan76 · 2025-05-28T20:31:02-0400

Tom Alpers said:
When you put the shaft in it are you holding the "release" button down? If not, try holding the release button down while putting it in. When its in, release the button and try it.

Hi Tom, I tried your idea multiple times in several different permutations. It didn't make a difference. 😒

Tom Alpers · 2025-05-29T01:22:48-0400

TbirdFan76 said:
Hi Tom, I tried your idea multiple times in several different permutations. It didn't make a difference. 😒

Bummer. Sounds like something has gone wrong inside. Possibly a rivet came loose and now a contact is out of position and jamming things up. I don't have a switch to look at but if it's like a lot of switches of the day you can get it apart by bending out little metal tabs around the edges that hold the backing plate/contact plate in position. Then you can take the plate off and see what's inside it.