Volvo RWD 444-544 Forum

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444 headlight switch 444-544

Any suggestions as to how best pull the headlight switch/cable assembly from the dash of a '57 444? Do I need to remove the instrument cluster to get into that tight area?

Or better yet, does anyone know where to get a replacement for the actual switch that sits on the firewall inside the engine compartment?
Thanks








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    444 headlight switch 444-544

    The switch can be removed without removing the cable assembly if needed and vice a verse.

    To remove the switch start in the engine bay by disconnecting the battery, then remove the wires from the switch after noting their positions, then loosen the set screw on the end of the switch shaft that retains the control wire to the switch, then you have work inside the car as you have to remove the nut that retains switch to the firewall. You might have to have someone hold the switch while your remove the nut.

    To remove the cable assembly, loosen the set screw on the end of the switch if the switch is still installed, then remove the nut that retains the cable assembly that is on the back side of the dash. When the nut is completely unthreaded from the shaft, you will able to remove the assembly by sliding out the assembly. If possible, try to grab the nut and the washer(s) before you pull the assembly all the way out or the nut and washer might get lost in the crevices of the dashboard. I don't think you have to remove the speedometer head with gauges to do this, but it won't be easy.

    Try not to permanently damage your neck and back during the process. It sometimes helps to remove the drivers seat, which in case you did not know will slide right off the tracks without the need of any tools. Simply slide the seat forward until it comes of the tracks and remove the seat from the car. With the seat removed, you can prop up a creaper with wheels removed on the seat tracks and on top of the pedals to support yourself. You might want to use some blankets or rolled up towels to support your neck and head while you are crammed in there.

    yourself by
    --
    Eric

    Hi Performance Automotive Service (formerly OVO or Old Volvos Only)

    Torrance, CA 90502








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      444 headlight switch 444-544

      Then I am on the right track. The nut on the back of the dash came only part way and then became stuck as if a thread is buggered. I'll need to find some way to keep the cable assembly on the dashboard from spinning so I can remove the nut the rest of the way. But it isn't easy.

      I like the advice about the creeper! I've been using some plywood but I hadn't thought about rolling up towels for neck support because that's the killer!

      Thanks!








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        444 headlight switch 444-544

        Great write-up, Eric!!

        You will not be able to find that switch anywhere. I was thinking of replacing mine ('58 444) with a new one due to corrosion, but they just can't be found. Only recourse is to install the 544 version in the dash and rewire it a bit.

        Be careful with that one, it's truly vintage!!!








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          444 headlight switch 444-544

          Although I have not done it yet, it might be possible to repair your switch.

          I have repaired some of the old Lucas switches used on Volvo 1800. My brother used to repair one of the Volvo 1800 turn signal switches before new ones became available for less money.

          I have seen at least one 444 with a modified headlight switch. Someone installed a modified toggle switch in the old switch housing. It was ugly, it had only one position so you could not illuminate just the running lights, but it did work.

          If you opt for this fix, just make sure the toggle switch can handle the amperage.
          --
          Eric

          Hi Performance Automotive Service (formerly OVO or Old Volvos Only)

          Torrance, CA 90502








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            444 headlight switch 444-544

            I've had the switch apart twice, cleaning up the contacts, renewing the paper (it's not paper, it's a thin non-conductive plastic-like gasket) between the sliding parts. The problem is the copper contacts inside are touchy. I can set the switch on, and all the lights come on; only to find when I return home that the tail-lights have been off for some unknown amount of time.

            Also, these were switched to not illuminate the front blinkers when the headlights are on. Parking position yes; headlight position no!

            I'm thinking of replacing it with a more 'modern' 3 position switch like found in 60s era Fords and such, including a rheostat for dimming the dash lights.

            Thanks for the replies.







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