Testing 4k - 5k window switches

[Pat]

elliott

I had the same problem with my 89 200TQ window switches.
They measured o-kay but would not work.  I broke one trying
to pull it apart and there was a black covering on the contact points.
I assume this limited the current thru the switch contacts.  After
cleaning them the switch worked great but was useless because it was
broken.  Some switches you can take apart and clean but I could not
do it on the 200's.  Have you tried WD40 in them.  I tried this and some
of the switches came back to life for a while.

Pat Korach
Kirkland, WA.

E Bavely wrote:

> Hello all...
>
> As I've learned on this list, other than door handles (go team DH!), it
> seems like items like window switches on 4k's and 5k's are often prone to
> failure.
>
> Being proactive and slightly looney about having spares, I picked up a bunch
> of spare window switches for a 86 4kcsq at a local junkyard.  I had no idea
> if these switches are any good (they were cheap), so I wanted to test them.
>
> With the help of an engineer at work, we used a voltmeter and schematic to
> test the resistance (function) of the switches in various positions.  A few
> turned out to be bad, while others tested ok or at least "made" acceptable
> connections when we looked at the amount of resistance on the voltmeter.
>
> The strange part is that when I took the supposedly "good" switches and put
> them in the car, they did not work as they should have.  Some would only
> work the window in one direction, others were flakey in general.
>
> I used a known good switch as a control, so I hopefully eliminated the
> possibility of having faulty wiring/motors in the doors. I figured that even
> though they tested fine, maybe some of the switches did not allow enough
> current to pass through and actuate the motors.
>
> Also, in the process, I managed to break one of the plugs for the switch in
> the 4kcsq and hacked up my fingers pretty badly trying to wedge my hand in
> the console to change plugs/switches five times.
>
> So here's the point:  I was wondering if it would be possible it to make
> some kind of test harness for this type of window switch (4k and some 5k).
> I have an extra plug/wire assembly from a similar car.  My plan was to just
> use male spade connectors, longer wires and "piggy back" into the existing
> plug that's in the car.  That way, I could connect into the plug in question
> with more working room and change switches at will.
>
> I'm not sure if this will work...one concern is the one wire that is
> actually connected to two places on the back of the plug.  I'm not sure what
> extending the wires and adding another set of wires/plugs will do to that
> wire and/or the accuracy of the test.
>
> A friend suggested rigging up a test harness using a car battery or power
> source, the plug end and then some kind of two-way motor or resistor for
> load on the switch.  Maybe I'm overlooking something or making this too
> tough...
>
> Has this been done before?  Any suggestions?  Easier ways to test switches?
> I probably have 10 or so switches now...it'd be nice to have a pile of known
> good ones to swap out instead of trying to fight with that tight quarters
> wiring...
>
> Thanks in advance...Sorry the post is so long...
>
> Elliott Bavely
>
> 86 4000CS Quattro
> 83 GTI FSP Racey car
> 83 GTI 16V
> 90 Cabriolet
>
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