Mondial ignition switch removal - Again

Miltonian,

In the last picture a couple of posts back you can see the top side of the contacts. In that pic look closely and you can see several small bars running between the contacts. Those bars are spring loaded and when in the "off" position are pushed down by small posts actuated by the switch.

In my case the contact on one of one of those bars was burned. I took the bar out and using a small file and some very fine sandpaper cleaned both the bar and its mating contact pad. I then temporarily clamped everything back together, plugged everything back up and cranked the car. Problem was cured.

The fix is not all that hard really. The most difficult thing, aside from getting the two halves of the unit permanently back together, was pulling the wires through the housing during the removal phase.

The contact pads within the switch, to my way of thinking, are way too small, smaller than the head of a straight pin. Not really big enough to carry the load expected of them. In contrast, the contacts in the ignition switch of my TR-6 are almost the size of a pencil eraser and they carry FAR less electrical load.

Paul