1990 XJ, standard GM style headlight switch.
Yesterday I went to turn the parking lights off while we had lunch out wheeling and the entire headlight switch fell into the dash. The knob prevented it from disappearing entirely and for the rest of the day I would turn off my lights by reaching under the dash, grabbing the switch and then pushing in the plunger.
Tonight I took it apart, removed the dash bezel, took off the gauge cluster, etc. and the hole that the switch is supposed to sit in, where the slotted locknut tightens down on the switch, was all broken and the hole had enlarged. I can only guess by the feel of the plastic that it has gotten hot over time and become brittle.
Since this is a conical shape and the switch attaches further back from the front of the panel where it's attached, I'm not sure what to do. It's all one molded piece of the dash and I can't replace just the damaged piece. It would involve replacing the entire dash on at least the left side.
First, has anyone ever had this happen?
Second, any brainstorms for fixing it?
I had thought at first about cutting out the bad piece and attaching a replacement cut out from the wrecking yard.
I've also considered a flat plate over the existing hole and having the switch stick out and extra inch. I could conceivably remove the knob and shorten the plunger rod since I wouldn't need the total distance anymore.
I'm hoping someone over time has seen a situation like this....help!
Yesterday I went to turn the parking lights off while we had lunch out wheeling and the entire headlight switch fell into the dash. The knob prevented it from disappearing entirely and for the rest of the day I would turn off my lights by reaching under the dash, grabbing the switch and then pushing in the plunger.
Tonight I took it apart, removed the dash bezel, took off the gauge cluster, etc. and the hole that the switch is supposed to sit in, where the slotted locknut tightens down on the switch, was all broken and the hole had enlarged. I can only guess by the feel of the plastic that it has gotten hot over time and become brittle.
Since this is a conical shape and the switch attaches further back from the front of the panel where it's attached, I'm not sure what to do. It's all one molded piece of the dash and I can't replace just the damaged piece. It would involve replacing the entire dash on at least the left side.
First, has anyone ever had this happen?
Second, any brainstorms for fixing it?
I had thought at first about cutting out the bad piece and attaching a replacement cut out from the wrecking yard.
I've also considered a flat plate over the existing hole and having the switch stick out and extra inch. I could conceivably remove the knob and shorten the plunger rod since I wouldn't need the total distance anymore.
I'm hoping someone over time has seen a situation like this....help!