I called the parts store and they are ordering a replacement switch.. They said that in the meantime, I could try to fix this one and they'd still take it back.. So I pulled the contacts back up and drilled through the plastic and the contact and pinned them in place with a little piece of toothpick..
Rung everything out, and still good.. Tried it in the truck, doesn't work.. everything but the variable speed works (pulse).. Took the module apart and measured resistance at the circuit board with the switch connected.. Can definitely see that the switch is connected and the resistance changes as the knob is turned..
So I guess I have a few options now... Repair the module (checked and a cross referenced Quad 2 input NOR chip is still available from Texas Instruments), or make a new one by copying this one. I might do both.. or I can make a new design based on this circuit, or I can design my own entirely new circuit, now that I understand how it works from the trucks POV... If I did that, I'd probably try to design something that is an all in one unit, (switch + pulse module), with the standard harness plugging into the back of that Like it does into the back of the module..
All the components are still available as far as I can tell (there's a couple transistors on the board I haven't checked yet) and I can cut a circuit board on the CNC mill (If I want to make some for sale or whatever, I can just design them on the computer and have a PC company print them for me).. It's actually a very simple circuit.. Very few components...
So, this little road to discovery caused me to ask the obvious question;
WHY HASN'T ANYONE DESIGNED AND MANUFACTURED A REPLACEMENT YET?
What am I missing? If these are as hard to get as they say, and there are as many people looking for them as there are, why hasn't anyone done this?
The only thing I'm having trouble finding (but I only looked for about 10 minutes or so) are the connectors/pigtails.. I think I found the empty 3 pin connector, and I found the 6 pin DELPHI-PACKARD part on a website but they are out of stock.. (Would have to contact them to see if this is a permanent condition or what)...
The two 'other' options I have is to install that tilt steering column from the 88 suburban I have, replace the motor/pump to match (haven't looked into how much hassle that is yet), get a module for that (readily available from what I can see) and adjust the wiring as needed (the option I plan to 'eventually do, but when I change the tranny to the 700R4 I have in the garage, but it's the most 'work' by far).. or to buy an expensive bolt in aftermarket wiper that has intermittent capability built in.. (Probably the easiest option but by far the most expensive)
Thoughts???
Thanks,
Mark