Door Jam Switch
 

Am still doing final assembly on my 68 coupe and installed the door jam switches this past weekend. Problem is the doors barely catch the edge of the plunger and won't push them back - only bends them sideways. Was very careful when we hung the doors and set all the gaps to the original specs. Re-checked all the gaps and the doors appear to be perfectly aligned. At most, I'm off a 1/16 of an inch in any direction. Any suggestions. Sure don't want to readjust the doors since that'll throw off my fender and everything else's alignment forward on. Nothing around the door jam appears to have been bent or warped. Can't imagine Ford's tolerances were that tight that the doors had to be perfect to properly contact the door jam switches.

There are two different switch models for your car year. Depends on whether or not your car has tilt wheel. Have you got the right type?

I ordered what was supposed to be exact reproductions of the original door jamb switches. I solved the problem however. Looked at pictures of the door jamb switches for earlier years in several catalogs and ended up ordering the switches for a 67 from NAPA. Got them in and the plunger was a lot shorter and much bigger in diameter. They worked perfectly and the doors catch them just right. Did have to remove the connectors and wire them directly since the male connectors for the 67 are a lot larger. Oh well, guess I'll lose a point or two for not having correct door jamb switches - doesn't bother me.

Sounds like you have a solution. My '65 uses the large plunger switch, probably the same one you found at NAPA. WRT to losing points you won't for daily driven or street driven classes under MCA rules. Perhaps if concours driven or trailered. Most importantly, it won't affect the insurance value given by most MCA appraisers.