repairing the 4-way hazard switch turned out easier than i thought.
after disassembly, the problem was a bit different than banzairunner's. the switch inards have a "racetrack" (for lack of a better word) that a sprung locating pin rides in. the switch maintains its "off function" when pushed in because the locating pin sits in a sharp bend in the racetrack.
i had two problems, first the short plastic lip on the right-hand side of the racetrack's sharp bend was worn and rounded off allowing the locating to slip off and not sit in the sharp bend, and second-the spring which should apply a downward force onto the locating pin was either worn or bent and was applying no force at all.
first, i reshaped the "bend" by cutting some plastic away with a utility knife blade (absolutly no room for error here-go slow), the result gave the locating pin a slightly deeper bend to sit in so the pin would sit in the notch more securely
second, i cut a small coil spring to fit between the switch case and the nonfunctioning locating pin spring, a dab of hot glue keeps it in place, do not glue the locating pin's arm as it has to be free to move.
the photo shows the racetrack with its inner boundary painted white for better visibility.
i did not wrap with wire and epoxy the case, if i did the fastening nut would not go over the increased diameter of the switch barrel. i think my switch was previously disassembled and because of the multiple disasssemblies now has 4 retaining snaps holding it together instead of the original six. but the four hold it together quite securely.
now to hope it never needs to be used!
nazgul
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