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Home > Technical > TD5 defender headlight failure - HELP PLEASE

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Kev stephenson

Member Since: 27 Feb 2012
Location: Huddersfield
Posts: 56

Dave-H wrote:
Kev stephenson wrote:
And the winner this weeks of 'diagnose that fault' is DaveW.

To all those that said it WILL be the switch........not always the case!!

Er - that IS the switch

It was the internals of the indicator stalk that melted not the light switch (i.e. the shorter stalk) 2005 110 TD5 XS running Alive Stage 1 and a bit and other toys
1996 130 300TDi chip truck for tree surgery business

19th Dec 2012 7:31pm

Kev stephenson

Member Since: 27 Feb 2012
Location: Huddersfield
Posts: 56

VeeTee wrote:
Kev stephenson wrote:
And the winner this weeks of 'diagnose that fault' is DaveW.

In my case however the plastic which holds the bit that you have soldered has melted meaning the flat piece of copper with the post on was sitting a few mm closer to the steering wheel and not making contact as it should to allow the headlights to work

A 10 minute job to change once I managed to get the steering wheel off (45 minutes!!!)

To all those that said it WILL be the switch........not always the case!!

Thanks again

Kev

??? Dit you read my earlier post:

Quote:
The melting light switch is a common failure, caused by poor design. All current is going through the switch contacts, after some time the switch will fail due to melting of the plastic which is holding the copper contacts. This *will* happen sooner (if driving much with lights on or towing) or later.

I told you it would melt... So the winner is...

It appears there is some confusion here, to me the light switch (as you called it) would be the shorter stalk used to turn the lights on!!

The problem I had was with the internals on the indicator stalk which operate the low beam/full beam switch.

Feel free to give yourself a pat on the back if you so wish 2005 110 TD5 XS running Alive Stage 1 and a bit and other toys
1996 130 300TDi chip truck for tree surgery business

19th Dec 2012 7:35pm

mk1collector

Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6771

Off topic but good to see another huddersfieldien on here

glad you got it sorted

19th Dec 2012 8:13pm

tasr12

Member Since: 09 Jun 2013
Location: Dorset
Posts: 228

2002 Defender 110 Td5 CSW Zambezi Silver

An old thread but hopefully someone can help me.

Got in the 110 on Wednesday at half 5 in the morning and no dipped headlights. Had side lights and full beam but not dipped. Had to drive to work on full beam as time was tight. Went to have a look around 11 in the morning and lights were all working normally??? Worked the next morning at the same, no issues. Went to come home this evening at 6 and original issue happened again...side and full beam no problem but no dipped headlights. Drove home on full beam, (sorry to anyone driving around Dorset!!).

Can anyone offer some advice. Common to both incidents is it being out in the rain prior. From the misunderstanding on this thread is it likely to be the small light on/off switch or the indicator/full beam switch that has failed?

Thanks in advance,

Tom. 2002 110 CSW TD5, Zambezi Silver
1995 110 CSW 300TDi - SOLD

6th Nov 2015 8:01pm

VeeTee

Member Since: 06 Mar 2011
Location: Somewhere
Posts: 1512

Very problably the light switch (short stalk), I would advise to fit relays in addition to a new switch, otherwise it will happen again sooner or later if you only replace the switch.

See http://www.defender2.net/forum/topic16451-7.html Cheers, Vincent
1959 Polynorm 1/4 Ton Trailer, Olive Drab Green (sold)
1970 M416 Military Trailer (Camping Trailer Conversion), Epsom Green (sold)
1975 Series III 88 V6, Light Green (sadly sold)
1996 Defender 110 CSW 300 Tdi, Epsom Green (sold)
2000 Freelander 1 TD4 3-drs, Silver (sold)
2006 Freelander 1 TD4 5-drs Facelift Automatic, Tonga Green (sold)

MySite

6th Nov 2015 8:27pm

tasr12

Member Since: 09 Jun 2013
Location: Dorset
Posts: 228

Thanks - read up on the relays earlier.

New switch it is then....wind deflectors will have to wait! 2002 110 CSW TD5, Zambezi Silver
1995 110 CSW 300TDi - SOLD

6th Nov 2015 9:00pm

tasr12

Member Since: 09 Jun 2013
Location: Dorset
Posts: 228

On the above - can anyone recommend a made up loom and what am I going to be looking at paying - £30? I've seen a Swedish one in other posts?

May take the hit and get the loom done as well, not ideal but I've got some miles in the dark next weekend so probably a good idea! 2002 110 CSW TD5, Zambezi Silver
1995 110 CSW 300TDi - SOLD

6th Nov 2015 10:10pm

davew

Member Since: 02 Jan 2012
Location: North Yorkshire
Posts: 888

1990 Defender 90 V8 Petrol PU Auto Rioja Red

tasr12 wrote:
An old thread but hopefully someone can help me.

Got in the 110 on Wednesday at half 5 in the morning and no dipped headlights. Had side lights and full beam but not dipped. Had to drive to work on full beam as time was tight. Went to have a look around 11 in the morning and lights were all working normally??? Worked the next morning at the same, no issues. Went to come home this evening at 6 and original issue happened again...side and full beam no problem but no dipped headlights. Drove home on full beam, (sorry to anyone driving around Dorset!!).

Can anyone offer some advice. Common to both incidents is it being out in the rain prior. From the misunderstanding on this thread is it likely to be the small light on/off switch or the indicator/full beam switch that has failed?

Thanks in advance,

Tom.

Assuming that you were using the normal high beam and not the "flash" function then it's not the short light switch it's the indicator/light switch. The main lighting switch provides power to the indicator/headlight switch and that directs it to dipped or main beam. If the short switch was at fault then normal high beam would not work either. http://www.yorkshireoffroadclub.net/

6th Nov 2015 10:30pm

tasr12

Member Since: 09 Jun 2013
Location: Dorset
Posts: 228

Dave,

Great answer thanks, from reading other threads on this I couldn't be sure.

Cheers,

Tom. 2002 110 CSW TD5, Zambezi Silver
1995 110 CSW 300TDi - SOLD

7th Nov 2015 7:11am

tasr12

Member Since: 09 Jun 2013
Location: Dorset
Posts: 228

Can anyone give me a steer on what a loom/relay and switch change will cost at an Indy? Trying to be proactive in advance of them opening as time is tight with work to get this sorted.

Cheers. 2002 110 CSW TD5, Zambezi Silver
1995 110 CSW 300TDi - SOLD

7th Nov 2015 8:23am

Cupboard

Member Since: 21 Mar 2014
Location: Suffolk
Posts: 2971

2011 Defender 110 Puma 2.4 HT Corris Grey

To fit a relay would be £20 of bits and maybe 2 hours. I think it took me about 3 hours including changing the headlights to Crystals, dealing with light guards and me not knowing what I was doing.

7th Nov 2015 9:27am

tasr12

Member Since: 09 Jun 2013
Location: Dorset
Posts: 228

Thanks. 2002 110 CSW TD5, Zambezi Silver
1995 110 CSW 300TDi - SOLD

7th Nov 2015 9:50am

VeeTee

Member Since: 06 Mar 2011
Location: Somewhere
Posts: 1512

You can buy a prewired relais and loom for approx. € 40. I installed it myself, took about an hour.
Easy mod, no wire cutting or soldering, and you can go back to original any time.

Click image to enlarge

https://shop.landreiziger.nl/lichtversterk...elais.html Cheers, Vincent
1959 Polynorm 1/4 Ton Trailer, Olive Drab Green (sold)
1970 M416 Military Trailer (Camping Trailer Conversion), Epsom Green (sold)
1975 Series III 88 V6, Light Green (sadly sold)
1996 Defender 110 CSW 300 Tdi, Epsom Green (sold)
2000 Freelander 1 TD4 3-drs, Silver (sold)
2006 Freelander 1 TD4 5-drs Facelift Automatic, Tonga Green (sold)

MySite

7th Nov 2015 11:18am

Mo Murphy

Member Since: 01 Jun 2008
Location: Letchworth Garden City, Herts
Posts: 2264

1984 Defender 90 BMW M57 3.0 Diesel HT Auto Pennine Grey

I'll second the above kit, it's nice quality and fits nicely. Buying from them is as easy as buying from a home retailer.
Mo The Land Rover 90 - Many are called, few are chosen.

50 Shades of Pennine Grey

7th Nov 2015 11:48am

tasr12

Member Since: 09 Jun 2013
Location: Dorset
Posts: 228

Thanks - will look at it.

More help needed though - just changed both the switches (small stalk and the indicator/dip/horn) neither has improved the situation! I still get sidelights and full beam but no dipped??

Any other advice before I re-assemble?

Thanks. 2002 110 CSW TD5, Zambezi Silver
1995 110 CSW 300TDi - SOLD

7th Nov 2015 1:43pm

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