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This is the second time I have replaced the PNP switch in my 960 and I decided to try something a little different to remove the switch. This time I removed the switch in about an hour and most of that time was spent thinking about it and setting up for the job:
As before jack up the front of the car and secure the front wheels on a set of ramps by setting the parking brake and chocking the back wheels.
Removal:
Put the car in "N" and with a 4 inch grinder fitted with a cutoff wheel, or similar tool, remove the exposed part of the switch shaft flush with the installed switch shaft nut.
Remove the two nuts, disconnect the connector, remove the wire ties and slip the switch off the shaft and off the car.
Install:
Dress the switch shaft with a file to remove the burrs; install the new switch, wiring, connector and tighten the shaft nut just enough to feel it tightly snug to the switch shaft…don't over do it; bend the keeper washer to hold the nut; install the other small bolt and tighten it enough to hold the switch to the body of the transmission. You will be tightening it down later.
Now place the car in PARK, and rotate the switch so the car will turn over the engine at that selection point…I used a screwdriver and tapped it lightly with a hammer to rotate the switch.
Check that the backup lights will turn on when the selector is in "R" and the car will turn over the engine in "N." Keep rotating the switch by tapping it easily until all three conditions are met, i.e., the car will start in "P" and "N" and the backup lights will work in "R;" tighten down the small bolt and re-check the operation of the selector one last time.
Notes:
In my opinion this is way too sensitive a switch and is too difficult to adjust for this application.
I believe the cause of the switch failure is it's close proximity to the exhaust system, without an aluminum deflector to reflect the heat; over time the switch is heat soaked many times and it fails.
By the way the brand of the switch is Scan Tech and it works fine at a much lesser price.
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