4kq headlight switch woes...

[Kneale Brownson]

At 04:42 PM 11/18/2002 -0800, Bernard Littau wrote:
>My instrument lights and all the outside lights other than the headlights
>have been intermittent lately on my '86 4kq.  Jiggling the headlight switch
>usually "cures" the intermittent problem, but did not this morning.
>
>I managed to get the headlight switch out from the instrument bezel, and in
>the process, the white wire pulled out from its crimp.  The white wire is
>for the headlights, I concluded with some experimentation -- so the
>intermittent with all the other lights is still a problem.  In disconnecting
>the headlight switch from the plastic block connector, the two gray wires
>also pulled out of the plastic block.  These gray wires may be for the
>instrument lights, as some of the gray wires lead to the instrument light
>brightness control.  Not sure where the parking lights wire into this
>switch.  Kind of wondering if bad crimps or a bad switch is the problem.
>
>Has anyone managed to get the spade connectors out of the plastic block to
>repair them?  How?
>
>I may be able to drip some solder into the back of the crimp while they are
>in the plastic block, and stuff the wires into them as a "repair".  Is there
>a better way? (As in, there must be a better way :-)
>
>I am debating just cutting all the wires and splicing in some new wire and
>new spade connectors, doing away with the plastic block.  I would be
>interested in any other salvage stories or ideas for this connector.
>
>Does anyone have the pin-out handy for the headlight switch?  I should be
>able to get it from the 4k Bentley when I get home, but I know that will it
>take some time to work through the diagram and numbers.

The real problem is the power through the connection at the switch.  Melts
the plastic in the connectors and possibly on the switch.  When I replaced
the one on my wife's 4kq campmobile, the switch and connector were one mass
of melted plastic with wires running out of it.  I cut the wires off and
spliced in new.  Got a new switch, the plastic connector block AND the
elusive click-in connectors from Carlsen Audi, but that was several years
ago.    If you have a dremel, you may be able to rescue the connectors from
the plastic block.