I took the switch out tonight and studied it for a moment. There are 6 contact points that open and close to let power through. The red wires in the middle of the switch are always hot. The big green wire is the culprit. When you turn on the key, the green goes hot and it will start. When you turn the key on and the green stays dead, its not going to start. Its that contact that apparently gets.... whatever they get, and won't actually contact.
So I took it out and fabbed a metal finger nail file on the grinder so I could get it between the contacts. I lightly filed each of the 6 contacts and put it back together. There are 6 tabs you pry out with about 4 hands and 2 screwdrivers to pop the top off the switch.
CHECK THE ORIENTATION of the cam that opens and closes the contacts and mark with a sharpie and don't let the cam come off the plastic base plate. Its ok if it does, just pay attention to how it goes back on.
So far, about 10 starts in a row without issue. Going to drive to work tomorrow and see if I get stranded.
DO NOT take out the little red painted set screws that hold the switch in place. Just loosen them as they are small and a royal pita.. whoops I said royal... go royals, bases loaded no outs!!! Anyway they are difficult to get back in.
The biggest bitch is the plastic retainer around the switch itself. Two #30 torx screws hold the cover on. To get one of them out, you have to use just a tip and 1/4 inch wrench.
Also need to cut the plastic wire ties to loosen the wire bundles.
Damn, 7 runs this inning!!!

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David
Imola Red 2006 4.8is