Petetheprinta
9th July 2013, 05:26 PM
Info for Disco 1 owners who may decide to replace ignition switch.
I had the proverbial problems with jiggling key for ever to start my 1999 300tdi Disco 1 so I decided to replace ignition switch assembly. Having read about it here and on other forums it didn't seem to be to hard for someone with my limited mechanical skills. I duly purchased a new replacement Lucas assembly took it to local locksmith and had it keyed to suit old keys. Proceeded to remove old one. I easily removed shroud on top of steering wheel but struggled with bottom one, it eventually came adrift after brute force in a shower of plastic pieces. Sadly I was unaware of third screw which you can only see when you lower fuse cover. I know next time.
I easily removed blind bolts with hammer and chisel but was now stuck getting connectors apart age and cigarette smoke had welded them together not a worry, screwdriver and hammer soon sorted. Now I notice strange wires soldered to ignition wires but have no idea what they are for, wire snippers fixed that.
Removing old assembly I installed new one. Beep beep beep beep instant sounding of key in ignition chime, bummer. Push key in and out no change, beep beep beep needs to be sorted cant drive with all that racket. Remove new assembly, nothing obvious. Put old one back in all ok. Did some basic continuity checks on new one and discovered that chime wires are constantly on,key in or out. Check old one, wires on when key in, off when out.
Long story short I returned assembly to locksmith and asked him to fix it as he had obviously stuffed something up. A very heated discussion ensued wherebye he denied all responsibility but refunded my money, dead end there. I finally compared with old one and noticed there is a small micro switch in assembly. When the locksmith had removed insides to re-key he had replaced barrel and in the process bent arm of micro switch so it was on all the time. You need to replace barrel with key in so that it misses the arm and continues to work properly.
A quick bend of arm and I was up and running with a lovely new switch assembly that works so well I am now able to make a quick getaway if I choose to rob a bank or something.
Wow this is very long winded, my apologies.
By the way the strange wires were for the after market sunroof which no longer works, that's next on the list to reconnect...Cheers
I had the proverbial problems with jiggling key for ever to start my 1999 300tdi Disco 1 so I decided to replace ignition switch assembly. Having read about it here and on other forums it didn't seem to be to hard for someone with my limited mechanical skills. I duly purchased a new replacement Lucas assembly took it to local locksmith and had it keyed to suit old keys. Proceeded to remove old one. I easily removed shroud on top of steering wheel but struggled with bottom one, it eventually came adrift after brute force in a shower of plastic pieces. Sadly I was unaware of third screw which you can only see when you lower fuse cover. I know next time.
I easily removed blind bolts with hammer and chisel but was now stuck getting connectors apart age and cigarette smoke had welded them together not a worry, screwdriver and hammer soon sorted. Now I notice strange wires soldered to ignition wires but have no idea what they are for, wire snippers fixed that.
Removing old assembly I installed new one. Beep beep beep beep instant sounding of key in ignition chime, bummer. Push key in and out no change, beep beep beep needs to be sorted cant drive with all that racket. Remove new assembly, nothing obvious. Put old one back in all ok. Did some basic continuity checks on new one and discovered that chime wires are constantly on,key in or out. Check old one, wires on when key in, off when out.
Long story short I returned assembly to locksmith and asked him to fix it as he had obviously stuffed something up. A very heated discussion ensued wherebye he denied all responsibility but refunded my money, dead end there. I finally compared with old one and noticed there is a small micro switch in assembly. When the locksmith had removed insides to re-key he had replaced barrel and in the process bent arm of micro switch so it was on all the time. You need to replace barrel with key in so that it misses the arm and continues to work properly.
A quick bend of arm and I was up and running with a lovely new switch assembly that works so well I am now able to make a quick getaway if I choose to rob a bank or something.
Wow this is very long winded, my apologies.
By the way the strange wires were for the after market sunroof which no longer works, that's next on the list to reconnect...Cheers