Rocker Switch LED Protection

Howdy, Howdy!

Heres my delimea... I am having some problems on some new rocker switches I developed and sell after I moved from incandescent bulbs to LED series... I am getting a small percentage of customers that are burning out the LEDs after a couple throws on the rocker but the rocker itself works just fine. My best guess is that they are getting zapped by field collapsing in the relay's coile and the coils do not have diodes across them. Since I do not have control over the quality of the relays being used by the customer, how can I protect the switch?

Here is a schematic of the switch and I also quickly drew a simplified with voltage drops.... it appears to have about 8.9ma through the line when using ohms law.... could I use a 12v Zener diode in front of the 1.2k ohm resistor to hold any voltage spikes at that level? Any food for thought on this would be greatly appreciated... also I only have enough room inside of the switch to handle 1 more component on the board for each LED in the switch.... otherwise I have to integrate something on the cross-straps externally on the back.... Thanks in advance.

If a Zener could do the trick... what size would be the right one?

Wow thats great! I'm feeling pretty stupid now.... Instead of Tunnel vision I think I had Zener vision. I cannot think of any reason why that wouldnt work either... I am going to do some testing this weekend on a couple known culprits (flex-a-lite fans control modules and  hella lights relays) that are my known diode eaters. I'll post back my results and let you know the outcome... 

I am feeling really really stupid.... I guess it pays to get up and walk away and take another look....or in this case have someone else take a look to point out the obvious. Most of the relays I have experience with are set up with anti-chatter diodes and run both AC and DC so I never really ran across a problem of the field collapsing... although the gear never had that sensitive of diodes in it either.

As for some switches absolutely....  I can hook you up with 5 or so for free and for you taking the time to post (very much appreciated). I mainly specialize in offroad items but if you go to my website ( http://www.4x4mods.com ) and check out the switch selections and available labeling I already have and just let me know what you are looking for. If you need some custom labeling done its not a problem either.... it would just take me about a week or so extra to get the time to get it layed out and made up.

One more question... what diode would you recommend.... 1N4001(50v) or 1N4002 (100v) be overkill.... yet still safe?

Thats great, I'll  run some different variances of voltages through a few different diodes in the circuit and do some smoke checks. Find out which components smoke first  and where the week links are. I picked up a fan from flex-a-lite for a guinea pig. I'd like to get these new 40 series switches just short of bullet proof if possible. I hate to smoke check a fan (hoepfully wont) but I'd like to get the switches to a point where I have absolute confidence in them.