Ford ignition switch frustrations

[john in kzoo]

I have the Ford ignition switch on my '15 touring. When placed in the batt position I sometimes, not all the time, have to push/tap the faceplate to get the coils to buzz. I have opened up the switch countless times to crimp/squeeze the brass contacts to make sure I am getting a consistent contact. Still acting up. My next thought is to replace the switch lever (part 4728)
thought????

[Susanne]

Take it aparMy 15 had a similar issue, IIRC I was able to clean up the contact "post" (mine was pitted and corroded) and give it a new life. Worst case scenario you may have to replace it and the contacts it sits in (do both while you're there)...

[Scott_Conger]

John

you will likely not find a better quality switch than what came with the car. As Susanne stated, the contacts must be clean and bright. This will involve a teardown of the switch to access all contact areas. Just crimping the contact is not enough if there is corrosion...and corrosion that interferes with operation does not have to be severe or obvious.

One hint is to ensure there is a slight "ramp" on each end of the pendulum portion of the 4728 switch (https://www.modeltford.com/item/4728.aspx) so that it will engage the curled lug and quickly increase pressure within the crimped connection. I would almost suspect that it is not fully engaging (rotationally) which is why a "tap" is necessary to make connection. A "tap" is a pretty benign event compared to the significant contact pressures that should be in the switch contacts. Clean more and bend less.

[john in kzoo]

Thanks Guys, I'll give it a good cleaning.....

John