Lighting - Brake Light Switch Installation Precaution
Group: 46Number: 04-01
Date: Feb. 17, 2004
Subject:
New Style Brake Light Switch Requires Care During Installation to Prevent Damage to Switch
Model(s):
Golf, Jetta 1999 --> 2004
New Beetle 1998 --> 2004
Supersedes T.B. Group 46 Number 03-01 dated Nov. 7, 2003
Revised brake switch Part No: 1J0 945 511D may be damaged during installation if not properly installed.
The revised switch Part No: 1J0 945 511D:
^ Currently supersedes brake switch Part Nos:
1J0 945 511A and 1J0 945 511B and
1J0 945 511C for the models listed (does not
include Eurovan).
^ Part Nos. 1J0 945 511B , 511C, and 511D may be installed only once, if switch is removed, it must be replaced with a new switch.
^ Can only be tested in the installed position.
^ Contains internal switch(es) which can be damaged if not correctly installed and adjusted properly.
CAUTION!
DO NOT depress plunger prior to installation.
Service
If brake switch requires replacement:
- Remove cover below instrument panel.
- Disconnect connector from brake switch.
- Identify Part No. suffix (A, B, C or D) of switch installed.
- Remove switch using the appropriate procedure for the Part No. suffix.
1. Brake switch, Part No: 1J0 945 511A, removing:
^ This switch can be identified by the larger (approx. 10 mm) plunger tip and square shaft (arrow).
- Remove brake switch by turning left 90°
Install revised switch Part No: 1J0 945 511D
(see Brake switch, Part No: 1J0 945 511D:
Installing below).
Brake switch, Part No: 1J0 945 511B, C or D, removing:
^ These switches can be identified by the smaller (approx. 4 mm) plunger and round shaft (black arrow).
- Remove brake switch by turning left 45°
When replacing after removal, install revised switch Part No: 1J0 945 511D (see Brake switch, Part No: 1J0 945 511 D: Installing below).
2. Brake switch, Part No: 1J0 945 511 D:
Installing:
CAUTION!
This version switch contains an internal switch which can be damaged if not installed and adjusted properly.
DO NOT depress plunger prior to installation.
- Prior to Installation, pull out brake switch plunger (black arrow) to full extension.
- Apply a light coat of lubricant Part No. G 052 142 A2 to end of plunger (black arrow). Lubricant is considered shop supply.
- Keep brake pedal in the up position (IMPORTANT! hold pedal up if necessary while installing switch).
- Push switch in and seat fully into opening (pressing plunger against pedal to adjust).
- Once seated, secure switch by turning it to the right approx. 45° (must be turned fully to it's stop! see magnified views below).
^ This action turns the plunger shoe into the correct orientation to make electrical contacts in switch operate as well as locks in plunger (arrow) adjustment.
Once installed, inspect internal stop pin of switch (inset) for correct positioning (see examples below).
CAUTION!
When installing, the switch must be rotated until it is fully locked and electrical connector is in the horizontal position.
^ EXAMPLE of INCORRECTLY installed switch. Internal stop pin (white arrow) is NOT seated fully against outer shell (black arrow).
^ EXAMPLE of CORRECTLY installed switch. Internal stop pin (white arrow) is seated fully against outer shell (black arrow).
- Connect brake switch connector. Operate brake pedal to verify proper function, then reinstall lower cover panel.
CAUTION!
Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information.