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Testarossa Ignition Switch replacement

Discussion in 'Boxers/TR/M' started by NashGTS, Apr 29, 2021.

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  1. NashGTS

    NashGTS Karting
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    Bryan phillips
    #1 NashGTS, Apr 29, 2021
    Hello F-Chat members,

    I feel it's time for me to give back. I've used this form for reference so many times for various repairs and advice. Most of my problems have been accounted for, I thank you all. However, when I had an issue with my ignition switch where it no longer kicked over the starter, I had to pave my own way as I could find no previous posts on the topic other than to replace the entire ignition assembly at significant cost. The other alternative I found was to add a separate push button ignition switch. This solution would deviate from originality which I didn't prefer.
    The issue I had was a failure of the physical contacts which carry the current from the battery through the ignition switch and fuse board to the starter. This is the white wire in the ignition switch. There is no replacement part for this. The supplier is Sipea for the ignition assembly. In the end I found that various Alfa Romeo ignition assemblies had the same switch assembly. I bought one on Ebay for $35. I removed the switch assembly from the Alfa and replaced mine. I had concern over the switch contact life and condition so I ended up opening the switch assembly, cleaned the contacts, lubricated and reassembled.
    The wire colors on the original and the wire colors on the Alfa did not match, so I ended up cutting the wires and soldering in the old to the new switch with heat shrink to make it a clean look. When removing the wires from connector block one needs to pay attention to their location in the connector block. Most importantly the two blue wires. While both blue, they operate differently out of the ignition switch and perform different functions. Then again, pay attention when cutting and soldering in the old wires. Pay attention to where you cut the blue wire from the old switch and attach it to in the new switch. Both blue wires allow current to flow in the first ignition position but one does not in the starter position. I'm going to try and attach a few photos of the switch assembly.

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  2. versamil

    versamil Formula 3
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    #2 versamil, Apr 30, 2021
    I have two Testarossa's with a relay installed RIGHT at the starter motor, that clearly were installed because of the voltage drop related to the long path to the starter solenoid. The relay has the hot lead hooked right to the main terminal of the starter for power Then the switched wire is attached to the start terminal on the starter. So your ignition switch only has to have enough current running through it to turn on the coil of a relay. For TWo cars- one with only 3000 miles on it, I think there must be a Ferrari technical bulletin out on doing this bypass. Anything and everything a person can do to lessen the load on the fuse box, the better off you are. Both cars use a 40 amp Hella relay.
     
  3. NashGTS

    NashGTS Karting
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    #3 NashGTS, Apr 30, 2021
    Thanks so much for the advice. I was thinking a relay would be a nice way to reduce the current draw through the ignition switch as my original literally had melted plastic and the contacts we stuck open due to the deformed plastic. When I opened the switch it wasn't fixable thus I replaced it. A relay is a nice way to save this one and pulling off the hot lead at the starter makes perfect sense. I just need to make it look pretty. cheers,
     
  4. Bucci

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    #4 Bucci, Aug 17, 2025
    I need that exact switch. I hear you can get the switch although wires may differ from alpha Remaro. Anyone tried that?
     
  5. turbo-joe

    turbo-joe F1 Veteran

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    #5 turbo-joe, Aug 17, 2025
    what is this?
     
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  6. theunissenguido

    theunissenguido F1 Rookie
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    #6 theunissenguido, Aug 17, 2025
    Translation English to Italian....by Google translation ;)
    Alhpa Remaro .....Alfa Romeo
    Vertaling voor Alfa Romeo wordt weergegeven
    Vertaal in plaats daarvan Alhpa Remaro
     
  7. NashGTS

    NashGTS Karting
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    #7 NashGTS, Aug 17, 2025
    Bucci,
    I don't know what your starting point is but my experience was one where it was difficult to find a switch with the exact same contact positions as the key turned. Contacts are opening and closing as the key turns so this sequence is important. My original attempt with what I thought was right from an Alpha, turned out to not be perfect. In the end, I drilled out the rivets of my original assembly and replaced all the contacts with ones from the Alpha Romeo switch. In short, rebuilt the Ferrari part with contacts and small plastic bits that had not deformed from heat. This worked in the end and has served me well for the last four years.
     
  8. turbo-joe

    turbo-joe F1 Veteran

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    #8 turbo-joe, Aug 17, 2025
    would be great and very good not always only trust the translations, also thinking a little logical

    from lancia the switch also could match or from fiat. at that time a lot of switches have been working equal
     
  9. Bucci

    Bucci Karting

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    #9 Bucci, Aug 18, 2025
    Yes, that is about where I am at. Buying something like fiat or alpha a doing the same thing. What part did you buy to harvest from?
     
  10. NashGTS

    NashGTS Karting
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    #10 NashGTS, Aug 18, 2025
    I don't recall the car. I looked for one made by Sipea which had similar construction. I might have bought a few off ebay looking for all the right bits and pieces. The construction is similar, the switch timing is what changes.
     
  11. Bucci

    Bucci Karting

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    #11 Bucci, Aug 23, 2025
     
  12. Bucci

    Bucci Karting

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    #12 Bucci, Aug 23, 2025
    Where did you find that. Nash? I need one as well
     
  13. Bucci

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    #13 Bucci, Aug 23, 2025
    How did you support the drilled robots especially the one holding the disk that turns?
     
  14. Bucci

    Bucci Karting

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    #14 Bucci, Aug 23, 2025
    Rivits
     
  15. Bucci

    Bucci Karting

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    #15 Bucci, Aug 23, 2025
  16. NashGTS

    NashGTS Karting
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    #16 NashGTS, Aug 23, 2025
    Hello, It's been four years so my memory is a bit foggy. If I recall, I used a small screwdriver to work over the flange on the larger two rivets and open up the two halves. The small rivets I don't recall if they needed to be removed. If I did, I probably drilled out the flange on one side. Once inside I could replace the worn parts. The disc that spins you don't need to touch. Inside the grey plastic housing are springs, contacts and small plastic bits that help guide the contacts. It's these small plastic pieces that I had to replace as they got too hot. I cleaned up the contacts, put it back together, reworked the rivets and assembled the switch housing to the key lock assembly. Hope this helps.
     
  17. Bucci

    Bucci Karting

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    #17 Bucci, Aug 24, 2025
    I does thank you. That might be where I am headed. Also was thinking if drilling two small holes in switch housing then submerging the entire switch in corrosive X then blow air in the two holes and turn disk to try and clean contacts.
     
  18. Rifledriver

    Rifledriver Three Time F1 World Champ

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    #18 Rifledriver, Aug 24, 2025
    I had to have a 512TR ignition switch rebuilt as a short in the ignition system melted it internally along with a lot of other stuff. O.D.D. Parts in Sonoma CA replaced the electrical portion by cannibalizing a Fiat switch. The electric part was an exact match.
     
  19. Bucci

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    #19 Bucci, Aug 24, 2025
    With the tariffs I can’t even get a Fiat. One into the country.
     
  20. Rifledriver

    Rifledriver Three Time F1 World Champ

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    #20 Rifledriver, Aug 24, 2025
    I am unaware of any tariff preventing importation of anything. Besides, there are Fiat parts sources that probably have many in stock. Have you even tried? The one that fixed my problem car was off the shelf. Every week I order parts from outside the US and have not once been told "NO".
     
  21. dave80gtsi

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    #21 dave80gtsi, Aug 24, 2025
    Midwest Bayless in Ohio will have one, cheap.
     
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  22. theunissenguido

    theunissenguido F1 Rookie
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    #22 theunissenguido, Aug 25, 2025
    Most of the shipping companies have stopped shipping to the US because of the tariffs. Most of the European, several of Japan, Australia and the list keeps growing every day. We have to wait and see what will happen...
     
  23. Rifledriver

    Rifledriver Three Time F1 World Champ

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    #23 Rifledriver, Aug 25, 2025
    I have been buying quite a few parts from England and Italy with no issues. I am in this business and deal with it every day. None of my suppliers have said a word about this. Just complaints about some cost increases.
    In any event lots of US suppliers with inventory here for Fiat parts. One that I have used many times was mentioned a few posts ago.
     
  24. samsaprunoff

    samsaprunoff F1 Rookie
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    #24 samsaprunoff, Aug 25, 2025
    Good day RifleDriver,

    I think the issue is not that shipping companies will not ship to the US, but rather many US importers are unfamiliar or unaccustomed in having to pay importation taxes on the goods that they are importing. This is in contrast to the majority of other Countries where there are almost always importation taxes with some Countries having a threshold to when the taxes become applicable. The US has been different in that it was more of a rarity for US importers to be billed importation taxes and other fees unless the importation value was sufficiently high enough. Now, we have shipping companies transporting goods to the US and the US Importer refuses to pay the ow enforced US import tax fees... and the shipping company now has to eat the costs of returning the goods to the shipper... or in most cases the shipper is now billed for the refused returned shipment. I suspect this is what is going on.

    Going forward, any additional costs to bring in goods into the US will be added to those goods... and so the price of those goods will be higher to the consumer. This is true for all Countries and not just the US.

    Cheers,

    Sam
     
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  25. theunissenguido

    theunissenguido F1 Rookie
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    #25 theunissenguido, Aug 25, 2025
    It is only decided over the weekend, so from now one it will be taking time to get things imported in the US.....and money from the US customers.
     
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