I just received my Highway 22 harness kit, and I was having this same problem with the shaft not catching inside the headlight switch. Watching this video helped me get it to lock in. Thanks!
I always use Highway 22 kit for all my projects, the best there is. However, I notice the quality control of the switches are not as expected. Like the headlight switch which always seem to have the problem of the rod misalignment and loss of clicks. There was at one time I had to take the whole switch apart as there was no internal connection for power. Even the insides were misaligned and had to do some serious bending of terminal points. I now have started using back the stock 50 year old one and works like a charm, probably for another 30 years I bet. GM Delco-Remy certainly did things right. You have a video made on this switch issue, it means that there is an inherent problem with it, and needs to be addressed. I'm guessing they're Chinese made
Was losing my mind getting this rod back in. It was inserting but not catching. Once in a while I'd hear a click but nothing, it would just pull back out. I thought maybe I had broke it, but two days later of random trying I heard the double click and it caught. This is a miserable system, but hang in there if this is happening to you, keep trying, It'll catch.
The AAW headlight switch is garbage. Never had so many problems with a headlight switch. Do yourself a favor and buy the stock one....the shaft fits right in...no problem.
Its ugly as well. Its like they found the ugliest, cheapest switch they could find to include with these expensive kits. Plus you have to drill a bigger hole in your dash to mount it.
