Fixed Honeywell Zone Valve micro end switch, V5C010SB3X147

Fixed zone valve micro end switch, V5C010SB3X147, on 22 year old heating system.
BE SURE TO TURN OFF ALL POWER TO THE BOILER AND ZONE VALVE ASSEMBLIES, BEFORE DOING ANY WORK IN THIS AREA. KEEP POWER OFF UNTIL PROJECT IS COMPLETED AND YOU ARE READY TO TEST THE MICRO SWITCH.
My symptoms were the boiler would not fire up when calling for heat on the two zones where the bad micro switches were located. Other things, like a bad Aquastat, or exhaust obstruction, which could throw the exhaust Safety Switch, or bad damper motor, or bad zone valve motor could cause the boiler to not fire. Be sure to trouble shoot all before attempting this fix.
TROUBLE SHOOTING TIPS:
If all other zones will fire the boiler, but one zone will not fire the boiler, then I would for sure look at that zone valve motor and or the micro switch on that zone.
If other zones are working properly, then you do not have a bad damper motor, DAMPER MUST BE OPEN FOR BOILER TO FIRE, or you do not have an obstruction in the exhaust, which would trigger the exhaust Safety Device. So most likely it is the valve motor or the valve micro switch, on that particular zone, causing the boiler to not fire, when heat is called for on that particular zone.
I would call bending the spring a temporary fix, because I do not know how long the bending of the spring inside the old micro switch will work. It may work anywhere from 20 to 10,000 cycles. Mine was still working after 7 days, while I was waiting for new V3-101 micro switches to be shipped to me.
The weird thing was my BAD micro switch DID HAVE CONTINUITY so at first I thought it was ok, but I had to push the button all the way in to get a continuity reading. Once fixed, by bending the copper spring, I only needed to push the button about half way in to get a continuity reading. This seems to be the difference between a bad switch and a good switch.
How to repair the old micro switch:
1. IMPORTANT TURN OFF POWER.
2. Remove Zone Valve Assembly cover.
3. Take the screw holding the motor off. Swivel the motor out and rest it on something so not hanging by the wires. If wire nutted on, remove wire nuts and move motor out of the way. You must remove the motor as the second micro switch screw is under the motor.
4. Remove the two screws holding the micro switch and swivel the switch out of the frame.
5. Remove the cardboard cover.
6. Using a small flat blade screwdriver to pry the switch apart at the two slotted notches.
7. With cap off, try to pry the copper looking spring down. Carefully push it down. Try to not dislodge it, as I did. If dislodged, it is hard to put back together. I managed to put mine back together after dislodging the spring from where it attaches, but it is not easy with fat fingers. Therefore, try not to dislodge the spring from its attachment, but do bend it down.
8. Check for continuity again and if you get continuity with the button only pushed in about half way or a small distance, then I think you have fixed it, like I fixed mine.
9. Put cap back on old micro switch, put card board cover on, attach micro switch into frame with the two screws. Install the motor. Turn power back on, call for heat and see if everything is working again.
10. Once fixed, by bending the spring down, my boiler would fire up again, with the old micro switch.
Once I received the new V3-101 micro switches, I removed the repaired V5C010SB3X147 micro switch, even though it was working fine, and tried out the new V3-101 micro switches. They worked fine, but here again I have no idea how many cycles they will work. Here is the link to the V3-101 micro switches and just know that you will have to make an alteration to them so they will fit into the frame of the V8043E1012 Zone Valve Assembly.
LINK:
www.ebay.com/itm/153819221889
Alteration to V3-101 switches:
1. Use a Dremmel cut off wheel and simply cut off the Side Bottom post. That Side Bottom post is not needed. Smooth with Dremmel grinding wheel so no sharp edges. Now you can put the screw, for the Side Top post, in from the Bottom Up. Connect a new red wire using the provided screw from Bottom Up. If screw is used Top Down, the top of the screw head will hit the metal frame. You will not be able to screw the new micro switch into the frame, because the Side Top screw, if put Top Down, will hit the top of the frame. This screw has to be put from Bottom up.
2. Put another new red wire onto the Top, top post using the provided screw. The Top, top post with screw will fit into the cardboard cover and frame just fine with no alteration required.
3. Put the card board cover on, screw the V3-101 micro switch into the V8043E1012 Zone Valve Assembly frame. Use wire nuts to attach new red wires to old red wires. You have just replaced the micro switch.
Good Luck and I hope this saves you some money by either fixing a bad micro switch or buying replacement switches.

[@georgecreaser6418]

This just bought me more time on my zone valve micro switch. Thanks a bunch.this is the only video I could find on taking that switch apart. I a tiny piece of yogurt container plastic onto the top of the little black button stick so that it hits and pushes up the contact lever a little bit sooner. Two thicknesses of yoghurt container thickness was too much. Probably a 1/16th or 1/32 thick. Thanks for this.

[@josheinhorn]

Are the new switches from eBay still working?