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I am curious to know if anyone has had a headlight switch fail due to leak in the air on either line. So not interested in failures of the rheostat or electrical portions.
I bought a new switch and found there was a leak in the vacuum switch on the switch unit. The vacuum switch is a very simple design and simple construction. It's made out of a light-weight metal like tin and has a rubber plunger inside the tin box that moves between the ports. Mine would not hold vacuum. I think what had happened is that the box got hit or was not square to begin with. It's possible that I bent it while installing . . . very fragile design in my opinion. I had to "reshape" the box until the plunger sealed correctly inside the box and held vacuum. I have not had any issues with it since.
Of course, I didn't realize that I had the issue until I got everything back together and dash/steering column secured. Live and learn . . . I didn't keep the original switch, so not sure if construction was the same or if the aftermarket parts are just that cheap . . . probably the latter.
A few years ago, there was a batch of bad 68-77 headlight switches on the market. It seemed that about half of the ones we got in leaked. I can't say that I've had a bad one in about 5 years now.
Besides the 68-77 Corvette, the switch was also used on the 68-69 Camaro RS and the 68 Caprice. Lately I've been getting them through one of the Camaro companies, not a Corvette company, which may be why I haven't had any bad ones?