Could someone give me some tips on how I could make the hot wire in the ignition switch fit better without play?
Background:
working under the dash, My clumsy self accidentally snagged the ignition wires. Nothing pulled out and I thought it was ok.
Did some test drives and everything seemed good.
Yesterday I took it for a real drive to pick some items up and the truck dies on me like it ran out of gas.
I thought the gauge was lying to me so I put more gas into it...
No luck there so it was towed home. Thinking the fuel pump went out I started there.
Fuel system tested good so remembering how I snagged the wires, I moved to the ignition.
Sure enough the hot wire into the ignition is loose and wiggles.
It is "snug" but it moves enough that it will stall the truck out.
I was thinking about liquid electric tape, but I'm hesitant to use it for this issue.
Is it possible to push the connector out of the switch so I can try and pry the contacts out a little to keep it from vibrating out of contact?
Or another solution possibly?
Seems like a stupid question but it isn't fun working upside down right there so the less time I have to "experiment" the better really..
The one wire gets fairly hot, so that is my reason for not going with the liquid tape, I'm concerned it would just melt it and create a bigger mess...

 

Your ignition switch has a harness block that is attached to it. If the wire is loose in that block,
1) you can remove that block and pop out the particular lug, pinch it in a little and re-connect
2) find another block through the parts stores, junkyards and splice in your wires
3) remove the block completely, put end lugs on your wires and install them on the appropriate tabs in your ignition switch.


For me, I chose #3.

 

Ok #1 was what I was wondering if it was possible to do. I shall give that a try.
the lug(connector) just needs adjusted for a tight fit again.
thank you

 

Try using a paperclip to get the tab pressed in to remove the lug.