Reverse Light Housing

[JackJosh]

Evening All,

it seems that every job that I do is awkward on this van lol.
Today’s issue started with an attempt to adjust the reverse light switch. Without having to put a great deal of torque into it, the thing sheared!!
My question is - Is it easy to just whip of the housing, use an ‘Easy Out’ or a drill to remove the damage thread and then reassemble with a new switch and gasket? Or, when I remove the housing, will I get a load of exploding springs and/or other issues?

any help, really appreciated. TVM.

[Aidan]

with the later gearboxes with the reverse switch held in the removable cover (M7, 11mm head machine screws with integral washers) the cover is easy to remove, be aware there is a big spring acting on the selector shaft which is a press fit in a groove on the inside of the cover, just make sure you have control of the cover as you remove the last screw, and also on 4 speed and Syncros there is a pressed steel top hat shaped part the spring is acting on so just be careful when removing the cover, the top hat sit on the circlip on the shaft. Also be aware there is an o ring seal fitted in a convoluted channel on the cover and there should be a paper gasket as well, fitted to all boxes from late 1987 but often missing or not fitted if box has been previously worked on. The paper gasket serves to limit corrosion of the mating faces, worth fitting if not present, and will shift the actuation point of the cam on the end of the selector shaft a dadge which may help with function as the end of the switch can wear the cam over time.
o ring is 094 301 278 A
gasket is 091 301 278 B

reverse switch should be fitted with aluminium washer 020 301 244

I'd recommend upgrading to the T4 switch using a new junior timer connector as the aftermarket switches both spade and plastic block terminals are pants ime, but this will mean doing some work on the wiring, but gives you a more robust connection with better corrosion resistance.

[JackJosh]

with the later gearboxes with the reverse switch held in the removable cover (M7, 11mm head machine screws with integral washers) the cover is easy to remove, be aware there is a big spring acting on the selector shaft which is a press fit in a groove on the inside of the cover, just make sure you have control of the cover as you remove the last screw, and also on 4 speed and Syncros there is a pressed steel top hat shaped part the spring is acting on so just be careful when removing the cover, the top hat sit on the circlip on the shaft. Also be aware there is an o ring seal fitted in a convoluted channel on the cover and there should be a paper gasket as well, fitted to all boxes from late 1987 but often missing or not fitted if box has been previously worked on. The paper gasket serves to limit corrosion of the mating faces, worth fitting if not present, and will shift the actuation point of the cam on the end of the selector shaft a dadge which may help with function as the end of the switch can wear the cam over time.
o ring is [url=tel:094 301 278]094 301 278[/url] A
gasket is [url=tel:091 301 278]091 301 278[/url] B

reverse switch should be fitted with aluminium washer [url=tel:020 301 244]020 301 244[/url]

I'd recommend upgrading to the T4 switch using a new junior timer connector as the aftermarket switches both spade and plastic block terminals are pants ime, but this will mean doing some work on the wiring, but gives you a more robust connection with better corrosion resistance.

Thanks very much for that and all makes absolute sense. I had seen both the o seal and the fibre gasket and wondered which one, now I know to get both.
I could see a spring on the diagram, so was concerned. I will loosen the fasteners carefully and ease it off. TVM for the advice on using the T4 switch, with a new connector as well.
 

[JackJosh]

Success, all out very easily, including the sheared thread. There was no paper gasket, just an o seal and a load of Hylomar.
it will go back together properly.
Thanks For the help