Thread: Defender TD5 Main Light Switch melted

had a similar problem. heres what i did for less then 10 bucks in total if youre up to it.

i changed me bulbs to 100watts instead of the 55 watter thats why it melted.

copper contacts fused into the plastic of the switch.

I drilled out the copper contacts, clean up the area a little and filled up the holes with rivets to use as contact points.

instead of connecting the wires back on the switch, i cut all the wires and stuff in a bosch relay . switch is fine all the while till now.. its been close to a year now.

Originally Posted by justinc

Hi Dave, isn't Drivesafe Traxide? If so, thats who I meant.

JC

yep thats the fella.....

Hi All,

My '99 Extreme 110 shut down the headlights while driving night time in the outback when the car was about 12months old. The copper pins in the switch had melted into a complete failure.

Replaced the copper pins, reworked the switch mechanism and presto lights began working. Also set up a bypass switch in case the main switch failed again (which still sits atop the steering column today!).

Eventually got the auto-elec to install a $15 Bosch switch on main lights (with slightly smaller toggle to turn off / on) and no problems since. From memory the stealer wanted around $180 for a new switch.

PJ

Like everyone else I've burnt out the switch and fitted a relay to solve the problem

can someone explain to me what the headlight relay the yellow one in the fuse box does?

on the rave cd page 149 connector c282

Originally Posted by tombraider

600kms puts you where?

Somewhere near Glendambo?

Rego is due so mine has done it. Plastic looks cracked so don't know if the rivet trick will work. I plan to build a new switch.