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I have all the dash back together except the headlight switch. I cannot get the rod to stay in. I tried the old one and new one and it does not lock in... Do I have to push the button in.. I also tried that and didn't work or is there some trick!
I've had the same problem when I've changed out the switch on two different cars - I found that you have to reach up under the dash and move the end of the switch a bit to get the rod to slide in and then lock. Just pushing the rod in from the dash side usually doesen't work because the end of the switch where the rod locks may be slightly out of alignment.
I don't mean to offer discouraging data, but the new headlight switch I purchased from a major vendor, worked fine for about a week, then it too failed to capture the headlight **** rod.
I was fighting some gremlins in the wiring of my 65 so I had the headlight switch in and out several times, and the final time I installed it the headlight **** rod would no longer stay. So out it came and one from a different vendor went back in.
I have had a couple of occasions where the slider inside the switch got knocked out of alignment with that outside button, and the rod wouldn't lock. I ended up taking the switch apart and moving the slider back into position. Then put it back together and everything worked just fine. I seem to remember that there's a spring or two inside there, so proceed slowly if you try taking it apart.
I had a similiar problem when I rewired my 63. I knew when I started my project that I might have a few issues because my car is a 63 and the cluster was a 65. The headlight switch on the cluster didn't match the connector in the harness. So I ordered a 63 switch. Prior to installation, I inserted the old **** and it worked fine. When I put it in the cluster, it wouldn't go in all the way. I ended up ordering a **** for a 63 that looked "almost" exactly like my old ****. It was a fraction longer. New **** worked fine. After this lengthy explanation, my point is , make sure that your harness, switch and **** are all from the same year vette.
Just faced the same situation on my '66. Got new switch thinking that was the problem, but it wasn't. I just had to keep jiggling and pressing the release spring under the dash until it caught. Found out the old one would work also after trying jiggling enough with it. You seem to have to hold your mouth in just the right way.