New headlight switch problem.....help!

[Outlaw]

So, bought a brand new headlight switch (BWD brand) and installed, right away the headlights started to flicker and then die. Obviously the thermal breaker in the switch keeps blowing. My question, is this more likely to be a faulty/defective new switch or could there be another problem upstream?

Checked EVERYTHING down stream, pulled headlights, checked connectors and all looks good. The old switch never blew but had corroded contacts for the park lights and dash lights and beyond repair. Would the original switch simply just handle more amps than the new? Any ideas?......its a long trip back to the parts store from where i live.

[azdave]

Sounds like a bad switch (thermal protection rating too low). Do you have the means to check the load on the system with a VOM or ammeter? A replacement switch should be rated the same as the original. No reason it should be less unless the manufacturer screwed up.

If it is the thermal protection device kicking in it won't be triggered by poor connections at the headlights, harness plugs or battey, etc. Poor connections cause lower amp draw, not increased amp draw. If the breaker is good but still trips then you are pulling too many amps due to a short to ground or too much load from high wattage headlight bulbs maybe?

It would really help if you could measure the load.

[bbodie52]

My research below shows that it appears that your local provider gave you an incorrect part.

I've never had to replace a headlight switch on a Corvair yet, but I did notice that Clark's Corvair Parts lists two different switches — one for 1960-63, and the other for 1964-69. I don't know what the difference is, but if you inquire at Clark's their technical support people may be able to tell you. The problem you are experiencing with your 1963 Corvair may very well be a compatibility problem with the switch you purchased locally.

I don't know what the local store policy is, but in many auto parts stores they will not allow returns on electrical components, so you might want to call them before making an extended drive to try to return your new switch.

Here is the part listing form Clark's Corvair Parts...

http://www.corvair.com/user-cgi/catalog ... N&page=84B

Part number C1330: 60-63 HEADLIGHT SWITCH

Weight: 0 lbs 12 oz
Catalog Pages(s): 84B,R,24
Price: $ 33.25



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I can tell you that I checked the manufacturer's website online catalog. The only headlight switch listed for a Chevrolet Corvair was not intended for a 1963 Corvair. I checked for a listing for a 1964 Corvair and came up with BWD Part No: s415. Is this the part you were given? (The BWD catalog does NOT list a headlight switch for a 1963 or earlier Corvair).





I checked this part number on the Advance Auto Parts website and inquired if it was compatible with a 1963 Corvair. The response was NO. When I rechecked but changed the target vehicle to a 1964 Corvair, the response was that P/N BWD s415 is an Exact fit for your 1964 Chevrolet Corvair.

http://shop.advanceautoparts.com/p/bwd- ... icle=false

I also checked the O'Reilly Auto Parts Website for a BWD s415 switch and found a similar result, as shown below. Their compatibility listing shows that the s415 switch is compatible with a wide range of Corvairs — all 1964 or later!

http://www.oreillyauto.com/site/c/detai ... &ppt=C0039


2 vehicles 1968 - 1969 Corvair 500
H6 - 2.7L 164ci 2684cc - 2x1BBL GAS OHV

2 vehicles 1968 - 1969 Corvair 500
H6 - 2.7L 164ci 2684cc - 4x1BBL GAS OHV

1 vehicles 1964 Corvair 95
H6 - 2.7L 164ci - GAS

4 vehicles 1964 - 1967 Corvair Base
H6 - 2.7L 164ci - GAS

3 vehicles 1964 - 1966 Corvair Base
H6 - 2.7L 164ci - GAS Turbo-charged

3 vehicles 1964 - 1966 Corvair Base
H6 - 2.7L 164ci 2684cc - 1BBL GAS OHV Turbo-charged

4 vehicles 1964 - 1967 Corvair Base
H6 - 2.7L 164ci 2684cc - 2x1BBL GAS OHV

3 vehicles 1965 - 1967 Corvair Base
H6 - 2.7L 164ci 2684cc - 4x1BBL GAS OHV

2 vehicles 1965 - 1966 Corvair Corsa
H6 - 2.7L 164ci - GAS

2 vehicles 1965 - 1966 Corvair Corsa
H6 - 2.7L 164ci - GAS Turbo-charged

1 vehicles 1964 Corvair Deluxe
H6 - 2.7L 164ci - GAS

4 vehicles 1964 - 1967 Corvair Monza
H6 - 2.7L 164ci - GAS

2 vehicles 1968 - 1969 Corvair Monza
H6 - 2.7L 164ci 2684cc - 2x1BBL GAS OHV

2 vehicles 1968 - 1969 Corvair Monza
H6 - 2.7L 164ci 2684cc - 4x1BBL GAS OHV

1 vehicles 1964 Corvair Monza Spyder
H6 - 2.7L 164ci - GAS Turbo-charged
2 vehicles

[Outlaw]

Thats odd that you found part #S415 on BWD website, cause i found, for the 60-63 cars, part #S414 is correct on various sites, which is what i have. Do you have a link to that site....BWD? I actually asked for the Standard Mfg part, which i believe is superior but wasn't in stock.

I spent hours upon hours checking every connection, harness, wire and come up with the same result. Even with only one light plugged in, it still blows the thermal protection. I don't have any means of checking amperage right now but I'm pretty sure if one headlight shuts it down, theres something up. It's driving me nuts and I'm usually pretty good with tracing electrical issues.

And the parts dealer WILL refund my cash if they want to keep a good customer.....I'm already pissed that they charged me $86.00 for it!

[bbodie52]

As seen in the pictures at the end of this post, there is a significant difference in the physical layout of the 1960-1963 Corvair switch and the switch used in 1964-1969 Corvairs. There is no way to mix them up. You may simply have a defective switch.

Thanks for providing the part number you were provided. As a result, I searched Google for BWD s414 and did find it to be listed as compatible with the 1963 Corvair...



http://shop.advanceautoparts.com/p/bwd- ... /3054624-P



$73.99


Canada Auto Supply also lists the switch, and their price is $38.68. But their website fails to provide any vehicle application information.

http://www.canadaautosupply.com/index.p ... s_id=67832

With a price of only $33.25, Clark's Corvair Parts still has one of the best prices for this switch...
Part number C1330: 60-63 HEADLIGHT SWITCH

Weight: 0 lbs 12 oz
Catalog Pages(s): 84B,R,24
Price: $ 33.25


Pep Boys lists the BWD S414 switch with the price set at: $81.39

http://www.pepboys.com/product/details/ ... tore=false

I also came across and interchangeability list...

Interchangeable Parts Bwd Automotive S414
Brand Sku Type Name Base Price Sellers

Standard Motor Products DS-156 Headlight Switch Standard Motor Products DS-156 $45.72 - $80.97
Standard Motor Products DS156 Headlight Switch Standard Motor Products DS-156 $45.72 - $80.97

Amazon.com

Standard Motor Products DS156 Headlight Switch
by Standard Motor Products
http://www.amazon.com/Standard-Motor-Pr ... B000CPIR3K
Price: $53.09
NOTE: The Amazon.com website does indicate that this switch is compatible with the 1963 Corvair and it is in-stock.



The Standard DS156 is also listed on the Summit Racing website for $51.97 The Summit Racing website does indicate it is compatible with 1960-1963 Corvairs.
http://www.summitracing.com/parts/smp-ds156


Here is a physical comparison between the BWD s414 (1960-1963 Corvair) and the BWD s415 (1964-1969 Corvair) switches. The electrical connector physical layout used is completely different.

BWD Catalog Vol 2 - Corvair Headlight Switches

[Outlaw]

Ok, turns out the new switch is defective.....geez, you think you got a new part, then spend a day testing everything else! Bypassed everything and plugged the headlamps directly into the switch and it blew right away.....cleaned up the old switch and plugged it in....presto! Worked fine!

[bbodie52]

Glad in the end you were able to get it sorted out. A lot of time invested, I know, but at least you were able to find a solution!