Today's project is fixing my flaky headlight switch....its apart and I'm cleaning things up....but wish me luck. One of those jobs where four hands are needed apparently. How the factory put this mess together is mystifying!

If you ever wonder about the switch's internal protection from overload (that makes your lights 'strobe' when active) I think that is what is in the second picture...

The fan-like disc is distinctive to the "095" headlight switch so I'm hoping I can get this PITA back together

 

 

Thanks Mike !

I got it...the trick is holding the plastic slider block with the contacts, springs and ball-bearing detent in the body while getting the wafer disc, spring and spacer on the front. I had to use the old trick with thin wire that's required for generator brushes.... Get the slider secured into the switch body with the wire...assemble the front shaft components, install into the metal housing, then cut and remove the wire and bend the tabs back into place.

Reinstalled and tested, nice, crisp operation and nothing flickers anymore. I sorta expected to see some arcing or burnt spots on the contacts considering the headlight current load - but no; none of that