Grayhawk,

Seems there can perhaps be some info that might be useful to more than just me concerning procedure, so I'll keep it public...

Barry,
 
Probably not the switch.  Of course there would have been no reason for you to read the LNC2 e-mails over the last few years but the Legacy hydro-electric gear system is very similar.  So are the problems that can arise.  You might want to search the archives for LNC2 gear related issues.
 
Your situation might be related to the pressure switches, the pump shuttle valve installed backwards, damaged relays, back pressure faking out the pressure switch so that it thinks it has reached the right pressure, pressure switches not set high enough, etc.  But, probably not the switch that controls the relays.

I'll check all that and report back to the list...

 
From your description, it does not sound like you are following the emergency gear down check list.  If you don't pull the breaker(s), after the pressure is relieved the pump will continue to run until the cows come home - this is not good nor is it applying any pressure to the actuators and, if it is wired correctly, might even cause the pump thermal circuit to open the selected relay but apparently that is not the case.

You are right, I didn't pull the breaker. The CB for my plane is on the aft bulkhead of the baggage compartment...flying the plane and getting it on the ground safely was my major concern. 

When this happens in flight have you just tried to momentarily crack open the dump valve and return it to the closed position to relieve the possible back pressure while the gear switch is in the down position? 

No, it was drilled into my head during training that you only have one shot with the dump...I followed the procedure.

 
When the pump is running does your "gear in transition" light come on?  If so, when you opened the dump valve (assuming you did not pull the breakers) did the light come on?

Now that you mention it, no, it does not. One of those pesky little things you notice but then forget to ask about....how do I fix that?

There are definitely disadvantages to not building your own airplane...but I have you guys to help - which is what makes this list so great! Any input is welcome...

Barry