OZvette72

Before you start, ensure the thread is clean and correct before proceeding.

FWIW!! ... When I recently had to replace my Ajar and Courtesy switches I noticed that things were not as they should be. Normally the nylon contact holders at the end of the switch would have small cutouts to catch the raised barb and stop the wire from pulling back out after locking into place, but this was not the case.

OZvette72

I made up a small rig to hold the switch using some threaded rod, two nuts and galv. plate. I placed a bolt the same size as the hole in the switch hole, closed the door and because my kick panel was removed, I pushed from behind till the bolt touched the door. Measuring the bolt with a fine screwdriver from the mounting point to the head of the bolt and with a pencil marked it showing me the travel the switch need to engage/disengage.

OZvette72

Putting the wire through and folding down the ends with a pair of pointy nosed pliers, (making sure to be gentle on the nylon and the contact) would ensure that they would never pull out nor disappear into 'no mans land'.

OZvette72

Should you be lucky, the end may unscrew making life that much easier. Now all that is required is the trimming of the contact ends which I used an old pair of nail clippers. The cut will need to be close so that the switch can fit back through the hole without creating thread damage etc.

I hope it may give you some ideas.