02 SC2 Intermittent reverse lights

[billr]

Can you retrieve the old one and cut it open, so we can get a better handle on how it is designed and how much could be trimmed off?

[mistahsnowman]

I checked both the old and new switches on the car today. Both reliably gave continuity, but only with the ball pressed pretty much as far as it would travel. I double-checked them on the vehicle and they did turn the reverse lights on (and remained on), but again only with the ball pressed to the limit of its travel. Seems like the issue here is definitely wear in the transmission, not my switch going bad.

So much for a 10-minute job haha.

[billr]

The OP is getting ready to send me the switches to trim down, try to get more reliable operation. Does anybody have good photos of the inside of the shift tower? I would like to see what the mechanism is that actually presses on the switch plunger.

[Waiex191]

http://www.saturnfans.com/forums/sho...9&postcount=70

http://www.saturnfans.com/forums/sho...=230898&page=9

If I have time I'll get a picture from my spare transmission tomorrow.

[billr]

Yes, if you can get a picture or two of what actuates the switch plunger it will help me help the OP; come up with a reliable "fix" for this issue. Thanks.

[Waiex191]

So it is all in the shift tower. Here is video 1:
https://youtu.be/gVPggnt4udk

And here is video 2.
https://youtu.be/GCUy7JRNQXI

[fetchitfido]

Well, that's an easy enough fix. Just tear down the tower, put a couple weld beads on the shifter arm and put it back together. Simple, just like those 30yr old 1000pc puzzles from an estate sale

Wonder if there's a easy/simple way to get the switch to sit lower/push further into the transmission? Even if you took off a bit too much on the tower surface you could use washers to move it back out.

[Waiex191]

Originally Posted by fetchitfido

Wonder if there's a easy/simple way to get the switch to sit lower/push further into the transmission? Even if you took off a bit too much on the tower surface you could use washers to move it back out.

A milling machine would make short work of it. Otherwise maybe chuck up an end mill in a drill press.

I could not see any wear on the part that pushes the switch. I didn't have the best visibility through the hole.

[billr]

Thanks, that is exactly what I was wanting to see. I/we will keep you advised if I can come up with an easy mod to the switch to make it more reliable.

[billr]

It is time to revive/update this thread:

The OP sent me two switches, one used and one new. I have set the old one up with a dial-indicator to check operating points and have some preliminary results. Total travel is .100", trip point is .040", and reset point is .045"

You read that right (and no typo), the hysteresis seems to be negative!

Obviously, I need to thoroughly check my setup and procedure tomorrow, with fresh eyes; and check the new switch. Stay tuned...