Ignition switch repairable?

[OR tojo]

Lately, while I'm driving around, the engine stops as if I shut the key off. After chasing around phantom electrical possibilities under the hood, it turns out the current candidate is the ignition switch, itself.
So I am running the ignition wire on the ACC terminal and jumping the starter too turn it over. Luckily it starts up easy.

Is there a way to repair the contacts inside the switch? I haven't located a replacement 1964 switch on the usual internet sites.

 

[Coolerman]

If you do attempt to repair it, post the procedure here. You can also "upgrade" your 1964 switch to the still available later switch. All you need do is terminate the existing key switch wires with female 6.3mm terminals and insert those into a female 4 pin connector. I have the terminals and connector...

 

[OR tojo]

I removed the switch and installed the "toggle/button" assembly.

The back side of the switch seems to be rolled in, so I will be cutting the metal to remove the contact module.

I would caution anyone attempting this to be in an area where it won't be difficult to recover the little springs and detent balls that will be falling out as it comes apart.

I found the bad spot on the IG contact plate shown here on the bottom. The "on" position of the rotating connecting plate is shown as well. The incoming power (AM) is the longer plate on the top right. The third point of contact on the upper left appears on the other side of the module as a small post. The starter contact (ST) is the top one and the accessory (ACC) is to the left

 

[Coolerman]

Awesome pics! First time I have seen the inside of an early key switch. So are you going to repair and use it, or was this just to see what was in there?

 

[OR tojo]

Oh, I am a fix it guy. More of the process will follow.

 

[Bear]

Thank-you, Tojo, for sharing the interior photos--looks very similar to the sliding contact system used in the early rotary headlight and wiper switches. Quite a bit of wear on those contacts from years of use.

Noticed you Dremeled the tabs on the outer case to get it opened. How will you keep the outer case secured when you reassemble it?

 

[ToyotaMatt]

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[thebigredrocker]

How will you keep the outer case secured when you reassemble it?

$5 on JB weld to win

 

[Coolerman]

I used JB Weld to put my dimmer switch back together after Dremeling it apart.
Dimmer Switch Tech

 

[OR tojo]

That looks a lot like what I am trying to accomplish, nice detail pics.

 

[OR tojo]

Mission accomplished! I made a jumper from the 3rd point on the contact plate to the ignition terminal by using a jumper.

then reassembled the switch the best i could with JB weld (@thebigredrocker to win the $5)

 

[OR tojo]

Made some dimples for the JB weld to grab and smeared it around to retain the module.

Good as new! well, no noticeable difference from the user end view.

I even had the locksmith replace the pins so the key turns smooth.

fun project, and hopefully some insight for anyone else working with an early FJ40 ignition switch issue.

 

[Coolerman]

Thanks for the complete follow up on this!
Who knew you would need blacksmith skills to fix a key switch!