Luca_d

Member
Hi,
My 2a/3 diesel ignition switch (Lucas 128SA) is playing up - anc. and starter both work (position 1 and 3, although position 3 is sometimes a little dodgy, only cranks when the switch is in a very specific spot) yet my glowplugs do no (position 2). Considering it will cost around $60-$80 to get a genuine Lucas switch to Australia, I figured I didn't have much to lose in stripping and rebuilding it - as it turns out, they're a very simple mechanism (although I'm still having the same issue post rebuild... bummer).
figured I'd make a post here as I can find zero other posts about fixing these things (or in my case, no fixing)

Like all sprung switches, when you pry them open, there are nasty little springs that try to spring away, thankfully I managed to trap all mine before they ran away.
upload_2021-9-8_0-54-8.jpeg

You can see how crusty those connectors are.
In my switch there were two balls and 5 springs, the two larger ones go in the two center holes with the balls on top, the smaller ones are spaced around the outside.
upload_2021-9-8_0-55-56.jpeg

With the springs and balls in their proper place, the next step is to clean and replace the copper contact plate, bumps facing upwards (the bumps line up with the smaller springs). [in the next photo the whole mechanism has been rotated 90 degrees anticlockwise].
upload_2021-9-8_0-59-44.jpeg

You can see how those balls fit in here.
Also, note how buggered two of those contact 'bumps' are, these correspond to the starter and glowplug contacts (the worse one is glowplugs), due to the amount of current running through these guys, I'd guess this wear is a culmination of both physical and galvanic corrosion.
This is where my issue is, as I wanted to see if cleaning it up would be enough to fix it, I didn't touch these 'bumps' at this stage.
upload_2021-9-8_1-5-5.jpeg

Cleaned up the mating face with the terminals, you can also see the corresponding wear here.
upload_2021-9-8_1-6-47.jpeg

All buttoned up, and... it's still broken.

My next step will be to take it apart again and see if I can do something about those crappy contact bumps, maybe a bit of solder or similar. When I do so (if I do), I'll update this thread.

Anyway, that's that for the moment.

Luca
 
Yes, I might end up doing just that, was/am hoping to repair the original switch.

fitting a relay isn't a bad idea anyway - much more reliable I suspect!
Something sudden came up and I didn't have time to finish my post above:rolleyes:
Yes, basically, use your switch to trigger relays, contacts will have an easier life. Them switches are only around £15 here (UK):cool:.
Silver solder would be better on your old contacts if they will take the process.
 
I’ll give the silver solder a go tomorrow (standard wiring solder is too soft, would last a few days I suspect), if I can get it to stick them sweet.
If not (and probably even if), I’ll hook up a relay (I actually have one in a box somewhere, so no big deal). As you say, it’ll allow the switch to last a little longer.

cheers
Luca
 

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