Overheating ignition switch

[sallysparkle2]

Hi, Has anyone suffered the problem of ignition switches overheating and then burning out? I have just suffered my second last night, the first only 18 months ago, on that occasion it was replaced and no wiring problem could be diagnosed. But now I think there must be a problem. It's rather dangerous as both times it has happened at night on a busy road and the lights just suddenly failed. Any suggestions would be welcome, also can anyone recommend a good auto electrician in the Edinburgh area?
Thanks.

[Red Westie]

The ignition switch fitted to the T3 is generic across much of the VW and Audi range cica 1980-1995. It is extremely common to get starter and light issues as a result of faulty switches. Poor internal connections cause a high resistance so heat and melting terminals are pretty common also.
A replacement costs under a tenner from GSF and takes about 45minutes to change (column needs stripping to remove ignition barrel housing in order to gain access to the single retaining screw holding the switch)
Martin

[CovKid]

And consider putting anything that draws a lot of current on a relay

[VWCamperfan]

The lights tend to do this to the ignition switches. Had same problem a few years ago. Got a completly different system now but as CovKid says, change them over to a relay system. (Info in Wiki).

[sallysparkle2]

Thanks chaps for info,
I had a chat with someone today who also recommended having another separate ignition switch fitted, by the sounds of things this makes sense. I know that the switch is in-expensive and simple to replace but what worries me is the not knowing when its going to burn out and leave you driving at 60 mph in the dark, it could cause a serious accident or as in my case which was a luckier scenario, I was in the middle of nowhere in the Scottish Highlands at night and had to call out the RAC, luckily I just had a phone signal. As this has happened to me twice now I dont have any confidence in driving at night..I think the RAC has a limit on callouts also!!

[Red Westie]

hmmm don't think 20 plus years for the original indicates the new one will prematurely fail...infact with a new switch fitted I think you can forget about any problems for at least the next 5-10 years might even be another 20.
Martin

[sallysparkle2]

hmmm don't think 20 plus years for the original indicates the new one will prematurely fail...infact with a new switch fitted I think you can forget about any problems for at least the next 5-10 years might even be another 20.
Martin

Hi Martin, this is actually the third one in nearly 3 years! As Ive only had the van that long I'm not sure of its past record, perhaps this has been a continual problem with it.

[CovKid]

Again, sounds like its got more current drawn through it than it should have. If you do have extra lights fitted or anything that consumes power, do check they aren't all reliant on the ignition switch along their path. Its not uncommon for people to wire in ancilleries from anywhere in the fuse box and even if you don't have Bobby Dazzler MkII Sooper Dooper spotlamps, you might consider rewiring headlights so they use relays anyway.

[sallysparkle2]

Its not uncommon for people to wire in ancilleries from anywhere in the fuse box and even if you don't have Bobby Dazzler MkII Sooper Dooper spotlamps, you might consider rewiring headlights so they use relays anyway.

That's a good point as perhaps previous owners have done some DIY. I'm not really clued up on elctrics but when I take it to the person who is, I will certainly get them to check. Definately going to use relays for the lights me thinks.
Thanks.

[CovKid]

You'll get brighter lights into the bargain too

Does sound (if you're going through so many switches) that its being asked to carry more than it can be reasonably expected to. They're not exactly frankenstein buzz bar connections in there.