The tip end of the rod is sharply pointed, Derek and there's just a wee bit of room between the tip and the bakelite end. Maybe 4 thousands of an inch. And bakelite can be extremely brittle. So the combination isn't a good one. I think the damage happens when the rod retainer groove gets worn, but apparently if you had a problem with a new switch that's not so. I was assuming your headlight switch was an original one. The import switches are different...not the same design at all, and I don't know where you would find a new Delco original switch today. Maybe somebody has some old stock on eBay, but it would be expensive as all getout. Take a look at this one (which I bought to study). Each of the brass rivets on top is a contact point inside the switch. I haven't opened it yet, but just looking at the top I can see a world of difference...and there is no way to release the knob rod.
~ Jon 1952 1/2 ton with 1959 235 | T5 with 3.07 rear end
