What part of the switches have failed? All the same way? The starter,
auxiliary, or ignition part? Melted, didn't turn, didn't turn off? Seen many
different modes. From experience it does seem to be crap shoot even from the
dealer with these things. A poor design especially with the headlamp load.
My favorite failure mode is key on, ignition on, turn to start and ignition
drops out while cranking.

This may seem silly but the way the switch is used can has an effect on its
life. The make/break action of the contacts is not ideal. There is a reason
good switches have that "snap action". You want to operate the switch in a
fashion so as not to make the contacts arc. Avoid turning the switch slowly.
You want to get to the position you want, especially for the starter. Go for
it and let it return to run quickly.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
Ed McLean
Sent: Tuesday, May 12, 2015 6:50 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Ignition/starter switch failures

Over the last year I have had 3 ignition/starter switch (111 905 865L)
failures after not having but 3 failures in the preceding 22 years, all with
the same Vanagon.

Has the quality of these electrical switches declined?  They look just like
they always have.

I haven't changed the load on the switch with recent modifications or
component replacements except for the starter so I don't think they are
being overloaded.  Does the gear drive TDI Jetta Bosch starter draw more
current for solenoid activation than the original late Vanagon starter?

Maybe I have just gotten a bad batch of switches?

Is there a particular brand of switches to steer clear of or is there a
brand that is superior to others?  One of these that failed was Meyle brand
and another was a premium priced one from Worldpac.  Does anyone have any
experience with NAPA's Altrom brand"

Thanks for any and all comments.

Ed