Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096" - NCRS Discussion Boards

Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

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  • David L.
    Expired
    • July 31, 1980
    • 3310

    Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

    Pictured below are 3 headlight switches (from left to right): Original 1963 Corvette switch stamped "095" (GM # 1995095 in Gr. 2.485), Replacement 1963 switch purchased from Stoudt Corvette about 1988+/-, and an original 1963 Chevrolet Passenger switch stamped "096" (GM # 1995096 in Gr. 2.485 also listed for 1958-1962 Corvette in my 1963 Chevrolet Parts Catalog).

    The white ceramic insulator on the "095" and 1988+/- replacement switch are the same but the "095" switch has a "spoked wheel" unlike that on the replacement switch and the "096" switch. I also have several "131" headlight switches originally used on 1964-1967 Corvettes & passenger cars that have the "spoked wheel" but a totally different white ceramic insulator.

    Question: Can a "096" switch be used on a 1963 Corvette? I sold my Early 1963 white Split Window Coupe (#1450) years ago.

    GM # 1995095 was discontinued sometime between Jan. 1976 and Dec. 1981 without a replacement part number. My 1981 Corvette Parts Catalog (Nov. 1981) lists GM # 1995096 for 1958-1962 Corvettes, nothing for the 1963 Corvette.

    Dave





  • Bob R.
    Extremely Frequent Poster
    • June 30, 2002
    • 1595

    #2
    Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

    I used an 096 switch in my 63 for many years and I noticed that the dash lights were very dim, when I located and installed a 095 switch the dash lights got noticeably brighter. All of the functions worked with the 096 switch just the dash lights were dim.

    Comment

    • Stephen L.
      Extremely Frequent Poster
      • May 31, 1984
      • 3156

      #3
      Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

      David, why don't you check the resistance (minimum and maximum) of the "dimmer rheostat" to see the difference, using an ohm meter. Post here and then we'll all know the differences of these switches.

      Comment

      • David L.
        Expired
        • July 31, 1980
        • 3310

        #4
        Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

        Originally posted by Stephen Lavigne (7553)
        David, why don't you check the resistance (minimum and maximum) of the "dimmer rheostat" to see the difference, using an ohm meter. Post here and then we'll all know the differences of these switches.
        I do have a mini tester and I will try to figure out how to make the test and report back. Apparently the "spoked wheel" is part of the rheostat which controls the current by varying the resistance. My "131" headlight switches used on 64-67 models also has the "spoked wheel".
        Thanks for the tip.
        Dave

        Comment

        • Dan D.
          Extremely Frequent Poster
          • November 5, 2008
          • 1323

          #5
          Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

          David, I'm not sure why the Corvette switches have the spoked wheel but I think (notice I said 'think') it may have been meant to act as a shield to help keep dust and dirt off of the rheostat element. It may also allow the contact to better follow the rheostat wire and keep constant, steady pressure on the wire.

          Over time the rheostat wire gets dry and dirty and this not only increases contact resistance, but it causes extra drag on the wire as the contact sweeps across the wire. This will eventually wear the wire until it breaks and then you have no dimming. The dash lights simply go out whenever you move the contact off its end stop.

          There is no repairing the rheostat wire when the wire breaks. The wire is embedded into the ceramic with a high temperature epoxy like material. I do not know what this material is, but it looks like a material that was used back in the 50s and 60s called 'sour rosin' (sp). No longer available but it was a very hard, very high temperature material. If one was to try and replace this wire, I don't know how you could dig it out of the ceramic without breaking the fragile ceramic, or where you could get a replacement resistance wire. But this is a very wide spread failure mechanism in these old switches. If one has one of these switches in service that still works but turns hard, feels scratchy when turned, or the lights flicker when the switch is turned, then my advice to you is to remove the switch and clean and lubricate the wire before it breaks and the dimmer fails.

          If you do this, do NOT use a dielectric grease as this grease is an insulator. In a previous post I recommended a graphite based grease called Dow Corning Gn-paste. Use a very thin film of this on the wire.

          As far as the resistance of the rheostat element goes, is may be that the resistance of the passenger car switch is different from a Corvette switch. How well the lights dim is a function of the number lights and their resulting DC resistance. Passenger cars may have a different number of dash lights.

          I have seen the repro switches where the wire looks exactly like the one you pictured. I have measured the resistance these elements to be 2.5 ohms. An original Corvette element measures 5 ohms. This repro element will not dim the lights correctly in a Corvette. With this lower resistance the dash lights will not get very dim, even when the switch is in its full clockwise position.

          If you have a switch where the dash lights are dim, regardless of the position of the shaft, this is caused by corrosion and resulting high resistance under the rivets that couple electrical contact in and out of the rheostat wire. Dis-similar metals cause galvanic corrosion, especially after 50 or so years. You have to remove the rivets in order to clean the connection.

          As far as your question goes, the passenger car switch will work as well as a Corvette switch as long as the resistance of the rheostat wire is the same. I believe your repro switch will work except for the dimmer function, which will not work very well. Measure the resistance of all your switches and see how close they are to 5 ohms and make sure there is no high resistance in the rivets.

          Hope this helps you.

          -Dan-

          Comment

          • David L.
            Expired
            • July 31, 1980
            • 3310

            #6
            Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

            Dan,

            Thanks for all of that information. I just bought a 7 function digital multimeter today at Harbor Freight for $4.79 with coupon and no sales tax. I couldn't find my old mini tester so for the price I could not resist. I have several other headlight switches ("131", "096", "122" and "147") that I want to test. I found a site on the web that shows how to test vintage GM headlight switches with one of these testers.

            It seems that one could just replace the original GM stamped steel plate with the 3-digit stamping onto a similar aftermarket headlight switch to make it look more authentic instead of paying hundreds of dollars for NOS GM switches. I can't remember if you can see the headlight switch part number on a 63-67 Corvette if you stick your head under the dash. My 66 is in storage.

            Dave

            Comment

            • Frank D.
              Expired
              • December 27, 2007
              • 2703

              #7
              Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

              I paid $165 in 2014 for an NOS GM '63 "095" switch from Corvette-Stop-Restoration Services......after some price negotiations....they weren't hundreds of dollars back then.. I took it apart and did some clean up and lube this winter...
              Reassembly is one of those jobs requiring a third hand...

              IIRC I also ran a 096 switch before that - can't say I noticed any difference in dash bulb brightness between the two switches.....the 63 dash lights are not much more than a "warm glow" even at the highest settings on the NOS switch (I went to LEDs recently as shown in the cluster pic).

              You can see the "095" number on the NOS switch if you roll under the dash.

              Putting the genuine base plate on a non-63 switch would be a lot of effort to fool the judges or just make you feel better...and some here will call it "cheating"...
              Attached Files
              Last edited by Frank D.; March 7, 2019, 06:03 AM.

              Comment

              • David L.
                Expired
                • July 31, 1980
                • 3310

                #8
                Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

                [QUOTE
                Putting the genuine base plate on a non-63 switch would be a lot of effort to fool the judges or just make you feel better...and some here will call it "cheating"...[/QUOTE]

                Frank,

                Isn't repairing original parts or using reproduction parts also a form of "cheating"? I have never had any interest in having my Corvette judged for points. The only points that I care about is how many the New England Patriots can score.

                Dave

                Comment

                • Frank D.
                  Expired
                  • December 27, 2007
                  • 2703

                  #9
                  Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

                  Originally posted by David Liukkonen (3775)
                  [QUOTE
                  Putting the genuine base plate on a non-63 switch would be a lot of effort to fool the judges or just make you feel better...and some here will call it "cheating"...
                  Frank,

                  Isn't repairing original parts or using reproduction parts also a form of "cheating"? I have never had any interest in having my Corvette judged for points. The only points that I care about is how many the New England Patriots can score.

                  Dave[/QUOTE]
                  I'm with you....

                  I caught some guff about putting a solid state voltage regulator in the original Delco housing which I don't see as any different than one of those expensive "reproduction" batteries with a modern AGM battery hidden inside... Different strokes for different folks I guess..

                  Enough said...

                  Comment

                  • Dan D.
                    Extremely Frequent Poster
                    • November 5, 2008
                    • 1323

                    #10
                    Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

                    Re-assembling these switches is a challenge. If you are not careful the springs can go flying. When re-assembling there are 3 springs to try and hold in place and under tension, and one has but 2 hands. But if you do three or four of them you learn how to do it and it then gets easier. The worst ones are the 56 - 57 switches. Those springs really go flying. I take them apart inside a cardboard box so I don't lose the detent parts when they release. Been there - done it.

                    -Dan-

                    Comment

                    • Frank D.
                      Expired
                      • December 27, 2007
                      • 2703

                      #11
                      Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

                      Originally posted by Dan Dillingham (49672)
                      Re-assembling these switches is a challenge. If you are not careful the springs can go flying. When re-assembling there are 3 springs to try and hold in place and under tension, and one has but 2 hands. But if you do three or four of them you learn how to do it and it then gets easier. The worst ones are the 56 - 57 switches. Those springs really go flying. I take them apart inside a cardboard box so I don't lose the detent parts when they release. Been there - done it.

                      -Dan-
                      I used an old trick similar to holding generator brushes in with a wire during assembly. I wrapped some safety wire around the switch to act as a "third hand" while I got everything together and stable... Once I got the housing on loosely enough to hold things in place I removed the wire and did the final assembly...bending the housing tabs fully into place.
                      Attached Files

                      Comment

                      • Edward J.
                        Extremely Frequent Poster
                        • September 15, 2008
                        • 6942

                        #12
                        Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

                        I always thought that I had a original 63 switch as the 095 was on switch , I wonder if its just a service replacement?? It has no spoked wheel. and the plastic piece is yellow in color not white. thanks Ed
                        Attached Files
                        Last edited by Edward J.; March 8, 2019, 01:56 PM.
                        New England chapter member, 63 Convert. 327/340- Chapter/Regional/national Top Flight, 72 coupe- chapter and regional Top Flight.

                        Comment

                        • David L.
                          Expired
                          • July 31, 1980
                          • 3310

                          #13
                          Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

                          Originally posted by Edward Johnson (49497)
                          I always thought that I had a original 63 switch as the 095 was on switch , I wonder if its just a service replacement?? It has no spoked wheel. and the plastic piece is yellow in color not white. thanks Ed
                          Ed,

                          I have a total of six "131" headlight switches (GM # 1995131) in my collection. Five of them came from 1964 -1966 Chevrolets in salvage yards and one from a 1966 Corvette dash that I bought at a swap meet decades ago. All 6 have the "spoked wheel" and the plastic piece is white on all of them.

                          I also have a "122" headlight switch from a 1964 Pontiac Tempest and a "147" headlight switch from a 1967 Chevelle and both do NOT have the "spoked wheel" but do have the white plastic piece.

                          The 1995095 switch was discontinued sometime between Jan. 1978 and Dec. 1981 as per GM Parts History (and Jan. 1978 Chevrolet Price Schedule) without a replacement part number.

                          Dave
                          Last edited by David L.; March 10, 2019, 10:59 AM.

                          Comment

                          • Bob W.
                            Very Frequent User
                            • December 1, 1977
                            • 802

                            #14
                            Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

                            Dave,
                            I also have a switch like Ed's yellow and no spoke wheel #095.

                            Bob

                            Comment

                            • David L.
                              Expired
                              • July 31, 1980
                              • 3310

                              #15
                              Re: Comparing Headlight Switches - 1963 Corvette "095" with 1963 Passenger "096"

                              Originally posted by Bob Winters (1653)
                              Dave,
                              I also have a switch like Ed's yellow and no spoke wheel #095.

                              Bob
                              This is what makes researching parts interesting.

                              Comment

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