JustJeff

After a spirited drive through the winding roads of the Minnesota Farmland on Saturday, I set up Sunday AM to wash off the bugs and dust.
After that, I experienced 2 classic TT problems.
Within 5 minutes of each other, and in my driveway, the brake light switch failed, as an intermittent, and the passenger door switch failed.
The display showed the passenger door as always `open'
I got the brake switch today, and tackled the door switch tonight.
I'm proud to say it can be fixed, and dismayed to find out, once again, Audi chose an inferior part, made in France, for this sub-standard switch.

Here is the culprit after removing the door latch assembly.
Piece of crap small plastic plunger broke apart inside the switch.
<img src="http://mk1tt.montebellopark.com/images/newswitch8.jpg">

<img src="http://mk1tt.montebellopark.com/images/newswitch6.jpg">

The switch is mounted at the top, open end of the door latch assembly.

The switch mounts in those 2 holes.
You can see this cam-type acuator here, that pushes the switch button in, as the door is closed.

<img src="http://mk1tt.montebellopark.com/images/newswitch5.jpg">

I rummaged through my parts-bins, and came up with an industry-standard micro-switch that has stood the test of time as my replacement. I'll bet I could take this switch and substitute it in any major factory machine still in use today, and it would work. I'll bet this switch has been in my parts-bin for 20 years. Why Audi chose to use such a cheap switch is beyond me. This one will out-last the car I suspect.
I had to drill a new hole to mount it 90 degrees from the Audi one, and them I will epoxy it in place.
<img src="http://mk1tt.montebellopark.com/images/newswitch7.jpg">

Here it is mounted and wired.

<img src="http://mk1tt.montebellopark.com/images/newswitch4.jpg">


Here it shows the cheap-o switch in the same plane as it was orignally installed, with the new one, screwed in and epoxied in place.

<img src="http://mk1tt.montebellopark.com/images/newswitch3.jpg">


<img src="http://mk1tt.montebellopark.com/images/newswitch9.jpg">

Here it is mounted and in place.

<img src="http://mk1tt.montebellopark.com/images/newswitch11.jpg">

I tested this and it works, and I'm re-installng it now.

TTinCT

good stuff Jeff as always.....thanks for posting!

TT_Nuge

Never cease to amaze Jeff, nice work like always.

HugeTTs

Soooomeeeewheeeereeee oveeerrr myyyyy HEAD.

kodeTT

i still wouldn't be able to DIY like you did.

MCPaudiTT - DEFCON 1

What all has to come out to get that latch assembly out? Inner liner? More?

shifTT

For future reference and for those without a parts bin. Some of these switches from Digikey look like they may work: <a href="http://dkc3.digikey.com/PDF/T062/1502-1516.pdf">Cherry snap switches (PDF)</a> Page 1 figure 3, DC water and dust sealed.

MCPaudiTT - DEFCON 1

Should we get a bag of a hundred and pass them out like candy?! ; )

shifTT

haha... door switch GB!

JustJeff

remove the door card, 2-12-pt screws in the door jamb,1 cable to the outer door handle, 1 elec. conn