Re: {Chrysler 300} Convertible top switch issue /hazard

From: chrysler-300-club-international@xxxxxxxxxxxxxxxx <chrysler-300-club-international@xxxxxxxxxxxxxxxx> on behalf of John Grady <jkg@xxxxxxxxxxxxxxxxx>
Sent: November 2, 2020 10:55 PM
To: chrysler-300-club-international@xxxxxxxxxxxxxxxx <chrysler-300-club-international@xxxxxxxxxxxxxxxx>
Cc: 'John Grady' <jkg@xxxxxxxxxxxxxxxxx>
Subject: {Chrysler 300} Convertible top switch issue /hazard

Hi all,

Following will be of interest to anybody with 57-67 (at least )mopar convertible , switches vary , possibly ---but the design to be described was common. I could see power window switches doing this too.

What happened :

While riding around , top down, I noticed ammeter fluctuating wildly to full charge for a full second or so then waving around and then normal ; I realized later in the drive, it was repeating about every 5-6 minutes. So I made mental note, damn mechanical regulator, (which I love!) must be burned points again , continued ride for 2-3 hours .

Once back , Top would not go up , it moved about a foot and just stopped. Tried again a few minutes later and it went up (whew-rain coming) . =What is this now? = (*breaker was still hotâ€¦.) . Pulled cable off battery fast.

So got into switch, the switch was actually â€œstuck onâ€? in down direction, so top was continuously trying to go down for 3 hours! But what happened was 20 amp circuit breaker would open after a second* (thank you god) cutting off power. Otherwise harness fire or burned up top motor , generator or regulator? . So it drew a lot of power (30-40 amps+ ) for a second , as motor was stalled dead at down, breaker opened , then generator replaced that power into battery , then back to normal till breaker closed again, repeat over and over . The reason it shows CHARGE, not discharge is top connects direct to battery + lead, power to top does not pass through ammeter. So when running top, it lowers the battery voltage, regulator turns on generator or alternator to â€œ full onâ€?, shows a big real charge, cannot keep up with that short, but tries, so you see a big full scale charge. This raises hell with regulator and generator and top motor. May burn them out.

So decided I needed a new switch ---went on Ebay , 220 each (!!!!) = Apparently a known issue . So two approaches,----- I found a 40A standard â€˜toggle switchâ€? SPDT and checked hole, bezel etc ; by drilling slightly more oversize, looked like it could be made to work. But non stock looking toggle bat handle. I had gotten that kind of switch before, for a 64 Mustang top motor upgrade (was manual top) from hydro E lectric , an online convert parts guy . Also had gotten 300 hoses from him.

As I had the old switch out , decided nothing to lose vs. 200$. So got it open by carefully prying back 4 die cast fold ins with small sharp dike or wire cutter, small screwdriver . Once open pretty simple, V shaped contact , looked ok, it sits on the middle feed contact, moves by lever bat â€œend â€œ sliding on inside of vee ,--- but all was loose , copper vee just flopping around(?) why it fell down and â€œmadeâ€? the close side of switch. It looked like missing a spring or something. Mystified ----how can this ever work?

Then I Noticed slider part of toggle is made of nylon , looks â€œswagedâ€? into metal bat that is the outside handle you move , but closer look , it is supposed to slide out . Inside the hollow nylon and up into hollow bat is a tiny spring like a ball point spring but maybe 1/16â€œ or 3/64â€? diameter . Repeat tiny. Nylon is supposed to slide out , pressed out by that spring. Which would hold vee straight in middle, and hold bat straight out. .

Stuck in there now , by rock hard grease!!! Same affliction as wiper motor park cams, hardened grease on nylon parts . So cleaned out with WD 40 , put 30 W oil on it reassembled , works great, back into car.

So, try the toggle on your top. If it is obviously real floppy in the middle, the spring may be getting stuck, or is stuck . When fixed it will self center pretty good â€“you can feel spring action . I had noticed mine was sort of sagging down, lot of play, but it worked, so what. Know better now! You might not be as lucky with harness etc.

Plus I know the hard way, that on 57-59, if you push â€œdownâ€? switch while top is still latched, (or it â€œpushes itselfâ€?) the big aluminum main arm in back will snap right off at the pivot boltâ€¦â€¦talk about unobtanium.

Heads up!

Stay safe ,

john

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