Hi all
First the standard disclaimer: if you break your switch, I am not responsible. You should really buy another switch first in case something bad happens. I ordered my switch from chevroletonlineparts, their PN 95297028 . It was about 30 bucks. I don’t know if this is a GM part number or not. This was their listing for a 2016 Sonic RS. This mod worked for my 2016 Sonic RS with factory fog lights. For any other Sonic application, I have no clue..
I got this idea from reading another post here about forcing the head light switch into the off position by merely taking apart the switch and removing a spring. I purchased the switch and took it apart, looking for the magic spring to remove, but none was visible.
After looking at the innards of the switch assembly, I realized that the switch rotated back into the DRL Auto position by a cam action, caused by 2 spring loaded steel detent pins, and the molding of slopes into the switch knob rotation assembly .
To prevent the switch from camming back into the DRL position, I carefully used a Dremmel to add 2 notches into the switch knob that lined up with the OFF position of the switch body. That way when the switch was rotated into the off position, the detent pins would catch the Dremmeled in notches, and hold the switch into the OFF position. Turns out this actually works quite well.
Start by using a small flat blade screw driver to un do the 5 tabs on the switch cover and remove the cover
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Once the cover is removed, the knob can be pried off the switch body. There are 4 tabs that hold the knob into place. I used 2 screwdrivers to pry back the tabs, and carefully pried up the knob assembly. Go slowly, there is a lot of friction holding the knob in place along with 2 clips that hold the fog light button in place.
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Detent pins visible inside the switch housing
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Turn the knob over. I used the switch lubrication goo as a location guide for where to dremmel in the notches for the OFF position
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Using the tip of the screwdriver, I scribed in a reference line for where to dremmel in the indents, and wiped off the goo.
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Next the tricky part. Using the appropriate bit for your dremmel, carefully notch the inside of the knob. I mounted the knob gently in a vice to hold it, and made several passes with the grinding wheel, slowly removing plastic with each pass. This part of the switch has very thin plastic, so don’t go too deep with the notches or you will go thru the switch..
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One side done:
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When you are done, the inside of your knob should look like this:
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I wiped out the plastic debris, then used a cotton swab to re distribute the left over grease into the newly Dremmeled dimples. Re assembly is in reverse order. Line up the knob so it can be pushed into the spot where the detent pins are in line with the DRL Auto position and push the knob all the way in.
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Then push in the fog light button.
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Then put on the top switch cover
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Rotate the switch to all its positions to make sure nothings is screwed up. If you were successful, the switch should now latch in the OFF position.
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Congratulations, you should have a head light switch that you can use to actually keep your lights off with.
First the standard disclaimer: if you break your switch, I am not responsible. You should really buy another switch first in case something bad happens. I ordered my switch from chevroletonlineparts, their PN 95297028 . It was about 30 bucks. I don’t know if this is a GM part number or not. This was their listing for a 2016 Sonic RS. This mod worked for my 2016 Sonic RS with factory fog lights. For any other Sonic application, I have no clue..
I got this idea from reading another post here about forcing the head light switch into the off position by merely taking apart the switch and removing a spring. I purchased the switch and took it apart, looking for the magic spring to remove, but none was visible.
After looking at the innards of the switch assembly, I realized that the switch rotated back into the DRL Auto position by a cam action, caused by 2 spring loaded steel detent pins, and the molding of slopes into the switch knob rotation assembly .
To prevent the switch from camming back into the DRL position, I carefully used a Dremmel to add 2 notches into the switch knob that lined up with the OFF position of the switch body. That way when the switch was rotated into the off position, the detent pins would catch the Dremmeled in notches, and hold the switch into the OFF position. Turns out this actually works quite well.
Start by using a small flat blade screw driver to un do the 5 tabs on the switch cover and remove the cover
Once the cover is removed, the knob can be pried off the switch body. There are 4 tabs that hold the knob into place. I used 2 screwdrivers to pry back the tabs, and carefully pried up the knob assembly. Go slowly, there is a lot of friction holding the knob in place along with 2 clips that hold the fog light button in place.
Detent pins visible inside the switch housing
Turn the knob over. I used the switch lubrication goo as a location guide for where to dremmel in the notches for the OFF position
Using the tip of the screwdriver, I scribed in a reference line for where to dremmel in the indents, and wiped off the goo.
Next the tricky part. Using the appropriate bit for your dremmel, carefully notch the inside of the knob. I mounted the knob gently in a vice to hold it, and made several passes with the grinding wheel, slowly removing plastic with each pass. This part of the switch has very thin plastic, so don’t go too deep with the notches or you will go thru the switch..
One side done:
When you are done, the inside of your knob should look like this:
I wiped out the plastic debris, then used a cotton swab to re distribute the left over grease into the newly Dremmeled dimples. Re assembly is in reverse order. Line up the knob so it can be pushed into the spot where the detent pins are in line with the DRL Auto position and push the knob all the way in.
Then push in the fog light button.
Then put on the top switch cover
Rotate the switch to all its positions to make sure nothings is screwed up. If you were successful, the switch should now latch in the OFF position.
Congratulations, you should have a head light switch that you can use to actually keep your lights off with.