Thread: Repairing D2 Auto Selector Switch - old one wanted for testing purposes

Here's one that I replaced on my 2001 D2 a few years ago.



Probably only damage to the switche/s located in the lower section where you can see the water has invaded.

I've actually got two cactus units (the second one hasn't been opened yet) so maybe if I send them to both to you, you could replace a few switches and make one good one, replace yours and then you should be able to also repair yours and return it to me so I've got a spare.

PM sent.

Also just check that it hasn't just come out of adjustment. They are spring loaded and if they are out slightly they will do funny things - you will see it on the gear selected display on the dash.

After re-reading the Ashcrofts advert, it may be suitable only for the stand alone transmission ECU they provide for auto conversions to Defenders, and may not retrofit a D2. I thought I'd mention it in case anyone reading this thread in the future is looking for a new XY switch.

Triumph Rover Spares have 2nd hand tested units with warranty for $275, and thy supply the later D2a improved version too.

A couple of cadavers (of XY switches) arrived today thanks to Xtreme.

The one pictured above seems to have suffered some water ingress, and the plastic spline on the selector is chipped. It will go towards technical research though.

The second unit looked clean on the inside. The plastic covers over the crimp terminals were removed and a spray and swish of contact cleaner seemed to remove some grime, by the change of colour. The selector wheel was removed & cleaned, as were the rubber o-ring seals either side of it. I sprayed them with CRC so they wouldn't dry from the contact cleaner, though I'll put some INOX on them later.

Hopefully this 2nd unit can be resurrected.

I'll get the step by step photos loaded up and posted in the next day or so. Tomorrow it should go on the car and we'll see if it works. I've heard the later D2a (03-04) units were better, so if the unit on the car cleans up and tests OK, then I'll probably re-use that one, though I'll fit this and check it anyway.

After the repair I'll come back and report on how it's going. It may not work, or only be a short term solution, but hopefully it will be a long term solution. Even as a short term solution, it could work as a "get you home" repair.

If anyone's already done this, let me know, so I know what I may have to anticipate.

Thanks, Michael2

Glad to hear that the switches arrived in time for you to investigate/repair and be ready for your 'helper' tomorrow.

I hope all goes well and that you (and your Disco) are back on the road soon.

Got your phone message - don't worry about the postage at this stage. Lets see how the repairs go first and what condition your switch is in when you pull it apart.

Thanks Roger,

My helper's got a work interview tomorrow afternoon, so I've had to make a start on the job late this arvo.

The cross member has to be dropped so the exhaust can be removed, or at least swung out of the way, as the D2a has a CAT in the way.

Given the late stage of the day, my broken foot and having to work on a gravel driveway. I'll probably just sort out one switch and get that back in. There doesn't seem to be any difference between the ones Xtreme sent and the one that came off.

Internally they're quite simple. 2 switches with 3 on/off positions. The construction is about the same as an indicator switch in it's robustness (or lack thereof). The barrel that turns has cam lobes on it and it activates the switches, generating a signal for the ECU.

- Job now done.
- No errors on the Hawkeye

At least this proves it can be an interim fix, hopefully I'll be able to report that it's a long term fix soon.

Step by Step Pics to follow.

- Michael2

well done.
hope it lasts for you and i look forward to piccies as i have had a couple of times my car has gone into limp mode and that same fault has come up so maybe something for me to look forward to in the future

A few q's;

Should this be considered as a preventative maintenence item?

Is the improved D2a switch a new part number or is it the same number with an updated part.

And it seems that the cats don't only help kill just the front drive shaft but this as well. Good thing they've gone.