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Ignition Switch replacement DIY

63090 Views 26 Replies 17 Participants Last post by  countypays
Hi guys, I'm a long-time poster on these forums but my last how-to on installing an iPod dock was archived so I'm showing up in the forums as a new user. Anyway, my beetle is now long in the tooth and has run into the dreaded ignition switch short.

Symptoms are as follows.
Unresponsive non-essential column stalk controls such as signals, cruise control, and washer. Though high beam still works.
AC, Fan out but Hazard, radio, and ASR switch work fine (didn't check heated seats). Everything else works fine.

In my case, the battery top fuses and wiring were in perfect order so I'm now going to need to check under the dash. As this is a bit of a do, I'm thinking of posting my process as this seems to be a regular issue with new beetles of this generation. I've poured through the forums and found a Jetta/Golf-based tutorial but not beetle specific found here.

p.s. Mod, if I've placed this tutorial in the wrong category, please move me, but since I have a 1.8t this is where I posted.
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For those looking to replace the Ignition Switch Connector and harness, I found the connector pigtail (with wires) part number 4A0 971 975 on Amazon for $30 and the ignition switch part number 4B0 905 849.
My understanding of the real cause of the problem is the OEM pigtail is a little short and the stress on the connector causes the connections to heat up due to the improper contact with the ignition switch.
My plan is to pump the new connector full of dielectric grease and make sure there's plenty of slack in the harness when I reassemble it with the new parts.
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