Bongo Fury

well as I wont be paying silly money for a new one and the dealer said he may get hold of one on the next shipment
I have decided to fix it myself.

here is the offending article

and cover off

its grubby and actually a bit is broken off of the switch pivot mechanism

luckily the bit had fallen down into the housing an i have araldited it back on.

and just to be sure a thin coat of plastic padding as well looks ugly but is pretty secure.

the switches themselves a feeble at this pivot point as well, so we will build up the
flimsy plastic with some more plastic padding!

here are the spring loaded locator pins which center the switch [do not loose them ]

I have pared off the PP to reveal the shape of the switch pivot and drilled right through the
locator pin housing and both sides of the switch to allow for a uprated axle

here you can see the [shiny ]metal axle.


I have done one switch this evening and will let you know the final results, after a bit of servisol contact cleaner
and some very light grease

So far the modded switch is firm and feels a lot more expensive than before

hang on I've only had the van for 4 days what am i doing I have the bug for sure.

Looking good, may have to rename you Misterfixit.....................

Switch pimp/repair has worked perfectly now I can pay the le payage man without getting out of the van! hoorah.

The most fiddly bit was getting the locator pins back in after drilling through the housing,
had to put a 'slug' of cocktail stick in there to pre-load the hole.

Excellent result. I too managed to get my duff switch sorted (different probs but same dismantling job) so it can be done. Has worked perfectly now for 18 months. I dismantled mine in a large pastic tub in case anything popped off and tried to disappear (getting easier for stuff to get away, with my ageing eyesight)

The Great Pretender wrote:Looking good, may have to rename you Misterfixit.....................

Nice fix , I managed to bodge mine with araldite until I got a replacement switch housing from Jaylee left over from his repair project. As you say, the trickiest bit is relocating the pins.

Yes, I am looking out for a spare 636? mx5? cluster as a back up for when the alraldite and Plastic padding fail, not too soon i hope

Mine lasted about 6 months or so I think, but it wasn't nearly as substantial as your repair.
I think I got my standby spare from a Eunos (MX3 import?) different connector, but easy enough to figure out which wire did what with Jaylee's help, tested & works fine for a fiver rather than stoopid money

Yep. The 636 jobbie (with a little fashioning) fits the original plate..
Even managed to use the clips to hold it in place..

The circuitry is different.
The third rocker switch is live when on though & doesn't act as a passenger window immobilizer like the original.
I use mine to trigger a panic function with the remote alarm & CL total closure system.

& as i've said before, i fancy the 626 is a much sturdier switch!

hi paul,did you check your wiring loom inbetween your door and body,thats what i discoverd after taking the switch apart and miraculously getting it back together..

Loom seems to be ok[ish] may strip it back further at a later date
Yes Jaylee I was inspired by your post, nice work but have yet to source a donor unit.

windows now go Up and Down which is nice

I must admit the initial problem i had with the switch was due to the door loom black wire being frayed & detached, i just repaired it & took up the slack..
The V bend seems to cause alot of the problems with the loom due to bending with the door movement.

As an aside. I also discovered the previous owner had butchered the electrics in the original switch, in an attempt to remedy the intermittent passenger window problem which turned out to be the loom in the first place.