While trying to figure out a short on fuse 5, I took apart the door contact switch, but botched putting it back together. I found these excellent photos in Brickpix that user Chuffsy posted back in October 2010. They deserve to pulled out of Brickpix and given a proper post!

Source: Page 39 of BrickPix, under Technical "Picture Type", no model
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Door contact photos - Disassembly, maintenance on 1991 740

Photos and Notes by Chuffsy - Thanks!
Some additional notes by 740_dan

This really is a clever little example of part design.

When working properly, a short push in of plunger with a twist, will turn off the door and overhead light, good for working on car with doors open, key in or out.


Tool needed t25 torx or phillips driver, small flat tip screw driver. Note rubber cover is torn


Don’t forget to clean the ground tab in the housing, that is grime on metal contact, same metal that is shiny ring for screw.


Insert fine tip flat screw driver as shown and press in and up gently, there are two sides to release catch.


Once slightly out insert screw driver as shown and pry up just enough to release both sides of catch.


At this point - Stop! Take a breath and pull out slowly because orientation of parts will be lost if it springs apart - See photos below


Note orientation




Note orientation


Important for reassembly! Orientation of small tab on plunger in relation to middle ground contact, almost opposite.




Remove ground contact from plunger; here it is the dirty


Clean all surfaces, very light sanding, use light coat of dielectric grease on all metal surfaces, even the screw
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I own a Volvo or Does Volvo Own Me? Try the easy to search Expanded Style FAQ Index http://40mph.com/Brickboard_700-900_FAQ_Expanded_Index_Version/

You could also get a can of electrical contact spray cleaner at Radio Shack. It cleans electrical contacts and lubricates at the same time. It's something everyone needs in their toolkit. Developed for rheostats, but will clean up a lot of stuff that is troublesome to disassemble.

Great work and to the FAQ! This kind of detail makes Brickboard invaluable for all owners. Thanks for sharing.
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See the 700/900 "FAQ" at the menu bar top screen left side.

Thanks Guys , This was a labor of love! They can now be be purchased new rather inexpensively. They are stll working after the cleaning.

Nice photos, Chuffsy!
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Art Benstein near Baltimore

If you think nobody cares if you're alive, try missing a couple of car payments.