Ignition switch not securely staying in on position

[Relyt]

So after a bit of searching and not finding out what i need to do.

Basically my electrical portion of the switch is less then a year old, and I have just replaced my mechanical portion of the switch. The car will stay on but the switch is not very securely locked in the on position, sometimes while driving in rougher conditions the switch can be bumped off.

So what part of the ignition switch is responsible for keeping the key in the on position?

More details:
My electrical portion of the ignition switch completely fell apart one night and I jumped some wires at the fuse panel to make it home, replaced that with a unit from WW (along with a hard start relay) and haven't had any problems electrically yet.
A while later my switch would not turn unless I pressed on the electrical portion from behind, I overcame this by just not letting the mechanical portion pop back out, thus not allowing the steering wheel to lock, when removing the key. The the ignition switch then started to have issues of staying securely in the on position.
So I replaced the mechanical portion with a Hella unit, it is the "new" style. Removing the old switch was extremely difficult, requiring vice grips, screwdriver for prying, and a hammer to help knock it out (yes I was pushing the tab in the hole), it did not give me this kind of problem the first time I removed it for the electrical portion. The old switch does not pop back out on it's own when the key is removed, and appears very worn. The new one turns easily and pops back out fine and everything. But it still is not very secure in the on position.
I also noticed that the housing, specifically the steering lock mechanism does not have the "guide pin" that the Bentley has pictured, and the housing does look worn, where the other pin rests on the housing edge.

So do I need a new electrical portion, mechanical portion, or is there something up with the housing or steering lock?

If it's the housing or steering lock where do I find parts, or is that something I have to find used?

Thanks,

-Tyler-
_________________
69 Beetle - Daily driver
1600 SP (unknown history)
30 PICT 1 w/power circuit (Volkzbitz)
205T (Bill)

[Multi69s]

I am 95% sure that it is the electrical portion, but it has been awhile since I changed one. However, when I did, I had to change it out twice, due to the first one going bad very quickly. If no one else chimes in you can answer the question for yourself. Separate the two parts, then turn just the electrical portion. If you feel indents, or stops as you turn it, then it is the electrical portion.
_________________
69 road Bug 2110
73 Squareback - 2L, T4, Automatic W/ AC
Gone, but many fond memories 69 Baja Bug 2010 - 5 Rib Bus Transaxle
Gone but not forgotten 72 Baja Bug 2010
My builds
T4 into Squareback http://www.thesamba.com/vw/forum/viewtopic.php?t=458944&highlight=
Auto Trans Rebuild http://www.thesamba.com/vw/forum/viewtopic.php?t=516066&highlight=
AC in Squareback https://www.thesamba.com/vw/forum/viewtopic.php?t=...highlight=

[Relyt]

I was pretty sure it wasn't the mechanical portion either. If I don't get another response I'll do just as you suggested (I should have thought of that). I know that new electrical switches are prone to failure.

I'll make sure to update as I figure things out, it's not bad now, but I know these things don't get better.

Thanks for the response and tip!
_________________
69 Beetle - Daily driver
1600 SP (unknown history)
30 PICT 1 w/power circuit (Volkzbitz)
205T (Bill)

[Relyt]

Yes, you were correct, it is the electrical portion. The plastic part that the mechanical switch enters to turn the electrical switch was cracking, and now it won't engage the starter.

I have one on order from the FLAPS, will be here tomorrow, but it looks like it is the 72/73 style, so I will be fabricating up some wires.
_________________
69 Beetle - Daily driver
1600 SP (unknown history)
30 PICT 1 w/power circuit (Volkzbitz)
205T (Bill)

[Tim Donahoe]

You might want to get another one--when you second one goes out--from Wolfsburg West. I hear they're the best.

Tim
_________________
Let's do the Time Warp again!

Richard O'Brien

[Relyt]

I'm on my third one now. the first came with the car, was it original? who knows. The second came from Wolfsburg West and lasted about a year. The third one I just installed, a 72/73 style one from O'Reilly's.

I had to cut the wires from my Wolfsburg West switch, most of the terminal ends came off rather then disconnecting from the spades, even though i used dielectric grease. I crimped and soldered on terminals and used shrink tubing around them. The new switch is not an exact fit, it doesn't fully seat down. So this throws the clamp down off which makes it so the turn signal switch assembly is a tighter squeeze. I may try sanding down the plastic housing to get a better fit.

I also ended up not using the smaller two terminals, S and P. As far as I can tell these both are for the buzzer, which no one likes.

But I will be ordering another switch from Wolfsburg West as I do not trust this switches quality, as well as am unsatisfied with it's fit.

But my switch is now securely in the on position and everything is working (except the key buzzer).
_________________
69 Beetle - Daily driver
1600 SP (unknown history)
30 PICT 1 w/power circuit (Volkzbitz)
205T (Bill)

[Multi69s]

Good to hear your back on the road.

The last time I had to replace mine, I got it from a VW shop that had been around for years. The owner told me that it was virtually impossible to get good quality ignition switches. He said that there was one vendor that did have them, but the cost was so high that the average consumer would never purchase them. I doubt that the situation has changed much over the few years.
_________________
69 road Bug 2110
73 Squareback - 2L, T4, Automatic W/ AC
Gone, but many fond memories 69 Baja Bug 2010 - 5 Rib Bus Transaxle
Gone but not forgotten 72 Baja Bug 2010
My builds
T4 into Squareback http://www.thesamba.com/vw/forum/viewtopic.php?t=458944&highlight=
Auto Trans Rebuild http://www.thesamba.com/vw/forum/viewtopic.php?t=516066&highlight=
AC in Squareback https://www.thesamba.com/vw/forum/viewtopic.php?t=...highlight=

[ashman40]

Would you mind clarifying a few things?

[Relyt]

I would be glad to clarify.

I did have a 71 style ignition switch, the female spade connectors that pulled off the wires were the ones in the trunk, such as connecting to the fuse panel or the plastic housed connectors going to the starter and headlight switch. I would have hoped that factory crimps would hold better, so that was just a comment on the quality of the crimping. I did cut the wires at the ignition switch.

The new 72/73 style switch fits perfectly in the steering lock housing, I was able to get the retaining screw in no problem. I believe that the end of the 72/73 ignition switch is hitting against the steering column portion that houses the steering lock housing. I don't know if this is a problem with all 72/73 switches or just my $11 O'reilly's switch.
_________________
69 Beetle - Daily driver
1600 SP (unknown history)
30 PICT 1 w/power circuit (Volkzbitz)
205T (Bill)

[Little-Acorn]

That's not the only direction it can move in.

My brother had a '68 beetle. Was driving on the freeway when the starter engaged, without him touching the key.

I had wondered what it took to break the crank in a VW engine, now I know.....

[Relyt]

Just an update:

My right turn signal was blowing a fuse. The ill fit of the switch and forgetting to put the plastic caps back on the screws was causing it.

So I put the plastic caps back on and pulled the switch again.

The 72/73 style switch has an angle which should make it clear so that the shift lock housing tests on the rim of the steering colum housing, but mine didn't, so I filed down the edges near the right side to help it fit better. It does fit better but I still need to file a bit more to make everything flush, or just get another 71 switch.

Is anyone able to confirm if all 72/73 style switches are like this or just cheap ones?
_________________
69 Beetle - Daily driver
1600 SP (unknown history)
30 PICT 1 w/power circuit (Volkzbitz)
205T (Bill)