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rossy

Member Since: 29 Nov 2010
Location: Co. Roscommon
Posts: 1296

2011 Defender 110 Puma 2.4 CSW Stornoway Grey

headlight main beam fuse keeps blowing ** FIXED ! **

earlier on I changed the bulb as it wasn't working on offside main beam. I noticed the 10a fuse had gone as well so I changed that too but..

If the engine is on everything works fine but if you operate the lights with the engine off the same fuse goes pop as soon as you flick the switch to main beam. I checked whatever connections I could see in case there might be water in them. There's a light grey coloured one on the bulkhead corner on the drivers side that looks like it comes apart but I didn't want to try in case I broke it so I just sprayed both sides with water dispersant

Can anyone throw any light on this gremlin ? thanks

Last edited by rossy on 23rd Feb 2012 5:00pm. Edited 1 time in total

11th Feb 2012 4:03pm

bpman

Member Since: 21 May 2008
Location: Oslo
Posts: 8069

2008 Defender 110 Puma 2.4 SVX Station Wagon Santorini Black

do you have any modifications to the wiring eg Aux. spot lights ?

if so, can you isolate these from the circuit and re-test ?

do you have a picture of the grey coloured connector ?

12th Feb 2012 8:26am

DAZ110

Member Since: 06 Dec 2007
Location: East Sussex
Posts: 2039

2013 Defender 90 Puma 2.2 XS CSW Barolo Black

Check for wire chaffing on the edge of the wing under the bonnet probably near the back left corner.

I posted about this on 1st dec 2009 under the subject: Headlamp wiring chaffed against wing edge
Do a search in my posts.

DAZ110

12th Feb 2012 12:19pm

rossy

Member Since: 29 Nov 2010
Location: Co. Roscommon
Posts: 1296

thanks for the replies

nothing extra fitted and the wiring seems to be well away from anything that can cause chaffing. When I can remember how to post a pic I will but following the wires from the headlight they go into this little connector (just under the steering wheel area of the bulkhead right under the seal where the back of the bonnet shuts).

We have had a monumental volume of rain here in the last few months and I'm convinced that has something to do with it. I wish I had a garage or carport. Our garden covers about an acre so I might have to budget for one in the future !

12th Feb 2012 8:36pm

rossy

Member Since: 29 Nov 2010
Location: Co. Roscommon
Posts: 1296

Click image to enlarge

many thanks Daz

I was on the verge of trundling up to the dealer but then I searched for your post. I followed your advice and traced the wires. Sure enough they were routed so tight against a brake pipe that chaffing had worn through the insulation causing a short so a bit of insulation tape and a cable tie to pull them clear did the trick and I can dazzle again.

I thought it might be beneficial to post a pic so everyone can check theirs simply because I can't be the only one with this problem.

So if you look at the picture three of the wires to the left of the grey connector are from your drivers side headlights. You can see that they go reassuringly into a piece of trunking. Trouble is the trunking is only about 5" long after which they are just taped together and vulnerable to chaffing. If you follow their path you can see if they are rubbing against anything - if they are it won't be long before they pop a fuse and kill the lights !

23rd Feb 2012 5:17pm

DAZ110

Member Since: 06 Dec 2007
Location: East Sussex
Posts: 2039

I don't like to say 'told you so', but I did tell you so, if you get what I mean....!

I knew as soon as you posted originally that you had the same fault as I had in the past.

Anyway, glad you found the fault and fixed it.

Cheers
DAZ110

23rd Feb 2012 6:13pm

bpman

Member Since: 21 May 2008
Location: Oslo
Posts: 8069

Thanks for the follow-up solution - ill be checking mine shortly

25th Feb 2012 6:39am

colinthill

Member Since: 13 Jun 2019
Location: Surrey
Posts: 3

hi new to the forum but found it searching for Defender main beam fuse blowing. Guess where I shall be looking this weekend to fix the problem. Is this why Landcover put the high beam on a separate fuse.

Now I have found this forum its top my list for Defender stuff.

Cheers Daz and rossy for the info and picture

13th Jun 2019 5:22pm

DAZ110

Member Since: 06 Dec 2007
Location: East Sussex
Posts: 2039

Crikey, this post started back in February 2012 !

13th Jun 2019 6:45pm

colinthill

Member Since: 13 Jun 2019
Location: Surrey
Posts: 3

Some design faults just reoccur, mine is an 02 plate 110

Cheers

13th Jun 2019 7:02pm

colinthill

Member Since: 13 Jun 2019
Location: Surrey
Posts: 3

sorted, yep the wire was chaffing on the edge of the down fold of the wing. well protected now.

Thanks

15th Jun 2019 2:11pm

DAZ110

Member Since: 06 Dec 2007
Location: East Sussex
Posts: 2039

15th Jun 2019 5:35pm

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