Headlight switch fix w/pics

tripleblackA4 · 08-19-2005, 04:34 PM

The following is an illustration of what I did to remedy a broken headlight switch on my 1998.5 A4. As I posted earlier this week, my switch failed while returning from a long three hour trip. The switch had never given any signs of trouble before and I was suprised by it's failure. This may work for you, it may not. As the price of these switches approaches $150, it is well worth a shot. I will describe the fixing of the switch only, not the removal of the switch as this may be found in the Bentley manual.

First, remove the four Torx head screws on the wheel side of the switch using a T-10 driver.

Next, carefully remove the cover to expose swich contacts, switch lever, white postion detent arm, and black switch pivot.

Carefully lift off the Switch lever, next remove the white detent arm, finally remove the upper and lower sliding switch contacts and black pivot arm noting the position of each. The lower sliding switch is the one that controls the headlights and was the specific problem in this case.

The lower sliding contact has two buss bars within it that are spring loaded. The shorter one is the headlight bar. Check that they both project from the housing the same distance and travel freely when depressed with a small screwdriver.

In this case, the plastic surrounding the buss bars had melted slightly (note discoloration), not allowing the bar to extend out and meet the contact points inside the switch housing.

I had to trim some of the melted plastic away with an Xacto knife to get the bar moving freely.

Finally, lightly clean sliding contacts with fine sandpaper and clean the contacts in the switch housing with electrical contact cleaner. Lubricate all contacts with silicone dielectric grease and reassemble the unit.

Hopefully this will rectify the problem permanently but who knows. Good luck.

Santorin_V6QM · 08-19-2005, 05:08 PM

Sounds like this should be put in the FAQ, good job!

BSK · 08-19-2005, 05:18 PM

matt719 · 08-19-2005, 07:22 PM

tripleblackA4 · 08-19-2005, 07:24 PM

tripleblackA4 · 08-19-2005, 07:25 PM

08-19-2005, 07:30 PM

hint: Yes, I did it.

BSK · 08-19-2005, 08:21 PM

David.Norton · 08-20-2005, 02:31 PM

08-19-2005, 04:34 PM	#1
tripleblackA4 New Member Account #: 43968 Join Date: Oct 2002 Posts: 145	Headlight switch fix w/pics The following is an illustration of what I did to remedy a broken headlight switch on my 1998.5 A4. As I posted earlier this week, my switch failed while returning from a long three hour trip. The switch had never given any signs of trouble before and I was suprised by it's failure. This may work for you, it may not. As the price of these switches approaches $150, it is well worth a shot. I will describe the fixing of the switch only, not the removal of the switch as this may be found in the Bentley manual. First, remove the four Torx head screws on the wheel side of the switch using a T-10 driver. Next, carefully remove the cover to expose swich contacts, switch lever, white postion detent arm, and black switch pivot. Carefully lift off the Switch lever, next remove the white detent arm, finally remove the upper and lower sliding switch contacts and black pivot arm noting the position of each. The lower sliding switch is the one that controls the headlights and was the specific problem in this case. The lower sliding contact has two buss bars within it that are spring loaded. The shorter one is the headlight bar. Check that they both project from the housing the same distance and travel freely when depressed with a small screwdriver. In this case, the plastic surrounding the buss bars had melted slightly (note discoloration), not allowing the bar to extend out and meet the contact points inside the switch housing. I had to trim some of the melted plastic away with an Xacto knife to get the bar moving freely. Finally, lightly clean sliding contacts with fine sandpaper and clean the contacts in the switch housing with electrical contact cleaner. Lubricate all contacts with silicone dielectric grease and reassemble the unit. Hopefully this will rectify the problem permanently but who knows. Good luck. __________________ 1998.5 A4 quattro 1.8t Factory Sport suspension APR Stage 1 Clarion Pro Audio DXZ655MP

08-19-2005, 05:08 PM	#2
Santorin_V6QM New Member Account #: 94520 Join Date: Jul 2005 Posts: 105	Re: Headlight switch fix w/pics Sounds like this should be put in the FAQ, good job! __________________ Replying to the wrong posts on audiworld since 02'

08-19-2005, 05:18 PM	#3
BSK AudiWorld Super User Account #: 54666 Join Date: Apr 2003 Posts: 16,823	add this to the faq if you wouldnt mind __________________ aim: afastgerman

08-19-2005, 07:22 PM	#4
matt719 New Member Account #: 66058 Join Date: Nov 2003 Posts: 107	My high beams turn off when I turn on the directional... will this fix my problem?

08-19-2005, 07:24 PM	#5
tripleblackA4 New Member Account #: 43968 Join Date: Oct 2002 Posts: 145	Thanks, if you guys want to move it that's OK. I'm not sure where FAQ is. __________________ 1998.5 A4 quattro 1.8t Factory Sport suspension APR Stage 1 Clarion Pro Audio DXZ655MP

08-19-2005, 07:25 PM	#6
tripleblackA4 New Member Account #: 43968 Join Date: Oct 2002 Posts: 145	It might, give it a try. mine didn't work at all. __________________ 1998.5 A4 quattro 1.8t Factory Sport suspension APR Stage 1 Clarion Pro Audio DXZ655MP

08-19-2005, 07:30 PM	#7
Joey T Guest Account #: Posts: n/a	Wow, I wonder if such a post is in the FAQ? hint: Yes, I did it.

08-19-2005, 08:21 PM	#8
BSK AudiWorld Super User Account #: 54666 Join Date: Apr 2003 Posts: 16,823	dont worry about adding it. i will do it. make sure you dont delete them pics though __________________ aim: afastgerman

08-20-2005, 02:31 PM	#9
David.Norton Audiworld Junior Member Account #: 63450 Join Date: Oct 2003 Posts: 555	At least til it melts again, but who knows, maybe another 7 years.

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