Just a note for the record, in case anybody has a similar problem. My D2 was doing this intermittent flashing M + S lights, which would usually go away with a switch-off/switch-on of the ignition. Talking to the previous owner, this issue had been years in existence. Last week it finally went to limp-home permanently. We had checked all of the usual suspects as described above, including changing the inhibitor switch (XYZ) with a known-to-work used replacement. No dice. Yesterday had the tranny ICU replaced (under the passenger seat), and all good. So it was the ICU itself.
[1] D2 Auto Selector Switch UHB100190.jpg
D2 Auto Selector Switch. p/n UHB100190
[2] drill out rivets.jpg
Drill out the rivets
[3] cover off.jpg
Cover Off
[4] discoloured cover suggesting water damage.jpg
A cover showing water ingress damage
[6] first tab off.jpg
Lift the tabs over the wire crimps
[7] lift the tabs.jpg
Tab off - wire crimps revealed
[8] 2nd tab off.jpg
Continue to remove the tabs
[9] all the tabs off.jpg
All the tabs off
[10] you don't need to mark the position of the wheel.jpg
I marked the position of the wheel - this is not necassary
[12] remove the selector wheel.jpg
Remove the wheel - notice O-Ring seal either side of it.
[13] selector wheel profile with black 0 ring.jpg
The wheel
[14] selector wheel cam lobes.jpg
The cams on the wheel that actuate the switch.
[15] contact cleaner.jpg
Clean with a contact cleaner that doesn't leave a residue
***This cleaner was corrosive and the contacts failed after some days - use non corrosive***
[16] prise out the whole assembly.jpg
Prise out the whole assembly - do not remove the tan coloured tabs, and the micro-switches don't have prise open tops.
[17] inner contacts.jpg
The silver contacts are moved by the cam on the wheel to actuate the micro-switches. These cams have a mechanical function (not electrical). They will wobble a bit, but test that when pushed firmly in, they have some spring resistance as the open the electrical contact.
[19] showing both sets of contact points.jpg
Here you can see the wiring and both switches.
The electrical contacts are on the outside of the assembly. Clean these well, they're like indicator stalk switches in the nature of their construction.
[18] outer contact points.jpg
The electrical contacts are on the outside of the assembly. Clean these well, they're like indicator stalk switches in the nature of their construction.
[22] seal with silicone and use small bolts and nylocks to reassemble.jpg
Remove the rubber seal and apply silicone to both faces, then reuse the seal and bolt it together using nylock nuts.
Thanks Michael !!
"How long since you've visited The Good Oil?"
'93 V8 Rossi
'97 to '07. sold.
'01 V8 D2
'06 to 10. written off.
'03 4.6 V8 HSE D2a with Tornado ECM
'10 to '21
'16.5 RRS SDV8
'21 to Infinity and Beyond!
1988 Isuzu Bus. V10 15L NA Diesel
Home is where you park it..
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