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Maverick

Member Since: 08 Mar 2008
Location: Inverurie!
Posts: 261

1996 Defender 90 300 Tdi CSW Alpine White

Full beam switch

Just replacing the switch for the indicators and full beam switch but the full beam stays on permanently.

Dipped (Should be, its actually in the flash posistion)

Click image to enlarge

Full beam (This works as it should)

Click image to enlarge

And suggestions as to how to fix it? Bit stumped...

Cheers
Ben Ben

Rebuilt 1996 black/white Defender 90 300 TDi

27th Feb 2011 4:00pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17402

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Is this the new switch or the old?

The usual problem is that the pedestals locating the contacts melt, allowing the contacts to move. My dip beam failed completely mid journey not long ago for precisely this reason, but I was able to bend the contacts and make the switch work again. I also cleaned the contact thoroughly since the only reason I can see why there should be so much heat build-up in the switch is due to high impedance in the contacts. It is surprising that this happens given that on the Puma both dip and main beams are relay activated.

The only official remedy is to replace the switch.

This does seem to be a recurring problem, and it is in my mind to try to come up with a more permanent solution. Possibilities incluse useing a thermosetting polymer (instead of the thermoplastic one on the present switch) to locate the contacts, or better cooling/heatsinks in the contacts.

28th Feb 2011 10:51am

Maverick

Member Since: 08 Mar 2008
Location: Inverurie!
Posts: 261

Thats the new switch, I attempted to bend the contacts but then I cannot get it to engage the flash, doesn't seem to move back enough. Think I'll send it back and get a new one.

The old switch has a problem with the dipped beam as well, when indicating with full beam on, the self cancel knocks it out of full beam, and can cause the lights to fail completely. Also, the indicators can randomly switch themselves off.

Ben

Rebuilt 1996 black/white Defender 90 300 TDi

28th Feb 2011 6:48pm

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