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tyrannosauROSS



Member Since: 24 Jun 2016
Location: Kent
Posts: 136

United Kingdom 2006 Defender 110 Td5 CSW Chawton White
Rogue dash cable
I’m trying to diagnose why my headlights are not working. I’m in the dash. Relay appears not to be the fault. I’ve checked the fuses in the cab fuse box. Both good.

Whilst in the dash I’ve found a cable that’s disconnected.

It is a thin orange and grey cable.

Does anyone know what this does and where it should go?

Im a TD5 ‘06 Defender.

My thoughts/ hope. Is that is is supposed to be connected to the switch stalks and that it’s an easy fix.

Headlights are recently swapped out for led and did work.
Side lights come on still but no dipped beam and no main beam.

Main beam only works when “flashing” it by pulling the stalk towards the driver.

Thanks folks

Ross
Post #735089 16th Oct 2018 6:26pm
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rallysteve



Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2196

United Kingdom 2002 Defender 110 Td5 DCPU Keswick Green
Cable you refer to is the antenna for the alarm unit.

Classic symptom of headlight switch failure!
Steve 02' 110 TD5 Double Cab Rebuild Thread
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Post #735090 16th Oct 2018 6:36pm
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tyrannosauROSS



Member Since: 24 Jun 2016
Location: Kent
Posts: 136

United Kingdom 2006 Defender 110 Td5 CSW Chawton White
So am I right in thinking this cable should stay as is then?

I’m just about to take apart the shrouds and test the switches.
Post #735100 16th Oct 2018 6:59pm
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BenB8man



Member Since: 22 Mar 2017
Location: Norfolk
Posts: 427

United Kingdom 2010 Defender 110 Puma 2.4 DCPU Stornoway Grey
I feel like I've heard so much about that little wire recently! Maybe it's just me.
Last chap is right though, that can remain as it is, or if you fancy, whilst you're in there, extend it up the A pillar to give yourself more keyfob range.

Have a look here :
http://www.defender2.net/forum/topic26097....ndreiziger
Post #735113 16th Oct 2018 7:30pm
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tyrannosauROSS



Member Since: 24 Jun 2016
Location: Kent
Posts: 136

United Kingdom 2006 Defender 110 Td5 CSW Chawton White
So it’s not the stalk switch. I get voltage there and it operates normally.
It’s Not the light because I have tested this direct to the battery.
At the light terminals I get 6v. Obviously there’s a problem.

At the interior cab fuse box. The terminals are all corroded. So maybe this is my problem?

I did have trailer electrics fitted. I today cut these off as they were heavily corroded and packed with mud.

I’ve insulated each individual cable so they can cause any shorts.

I’m stuck. And at the moment I can’t drive the car at dark. And as winter is approaching this is going to be an issue.

Anyone else have any ideas?

I assume the circuit is battery, switch, fuse, “relay” that does nothing behind the clocks, lights.



Click image to enlarge
Post #735184 16th Oct 2018 11:09pm
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300TDi CSW Phil



Member Since: 03 Apr 2016
Location: Bracknell
Posts: 746

United Kingdom 1995 Defender 110 300 Tdi CSW Epsom Green
Did/does your defender have the dreaded dim dip relay fitted?

This causes havoc with LED headlights and will need to be bypassed for them to function as intended. 1995 300 Tdi Epsom Green - It's a keeper.
Wide Track Sankey- In bits- Gone to a new home
M0XQS
Post #735185 16th Oct 2018 11:14pm
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tyrannosauROSS



Member Since: 24 Jun 2016
Location: Kent
Posts: 136

United Kingdom 2006 Defender 110 Td5 CSW Chawton White
It has the relay that has only has two legs behind the clocks. Part number 10003 or something. It is not the dim dip beam one.

It’s all very annoying.

The lights were working fully when I first installed them.

Then they stopped.

Then they worked.

Now they don’t.

But it is not the switch and not the relay behind the clocks. And not the lamp itself.
I believe the earth to be good as we have tested this.

So for some reason I get a huge voltage drop between the dash and the lamps.
Post #735188 17th Oct 2018 12:14am
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tyrannosauROSS



Member Since: 24 Jun 2016
Location: Kent
Posts: 136

United Kingdom 2006 Defender 110 Td5 CSW Chawton White
Maybe there is someone in Kent who is a great auto electrician?
Post #735189 17th Oct 2018 12:16am
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tyrannosauROSS



Member Since: 24 Jun 2016
Location: Kent
Posts: 136

United Kingdom 2006 Defender 110 Td5 CSW Chawton White
Bulk Head fuse holder
There was someone on here a little while ago that replaced his bulkhead fuse holders. I think his were corroded/melted and he managed to source a replacement.

Can anyone remember this post? or point me to the part number. I want to install new, un-corroded ones.

Thanks
Ross
Post #735193 17th Oct 2018 2:07am
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landy andy



Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5416

2006 Defender 110 Td5 USW Zermatt Silver
When you had your old lights in did they use the dim dip system?

This is when the headlights go to half brightness (6v) when you have engine running and switch set to side lights. It makes the main bulbs glow dimly (and kill the bulbs). Normally this system is fitted to commercial variants not county’s with headlight levelling. It’s controlled by a pink relay behind dash binnacle which can just be bypassed.

When the main switch fails it’s due to the high current making the contacts in the switch get too hot and melting themselves into the plastic, so not making proper contact anymore.

90% of lighting problems are main light switch or dim dip so that would be my first points to look at.

Andy.
Post #735198 17th Oct 2018 4:59am
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MadTom



Member Since: 10 Sep 2013
Location: Olomouc
Posts: 572

Czech Republic 1999 Defender 130 Td5 HCPU Baltic Blue
I had not working dipped lights on our 130 TD5, and in was in connection headers hidden behind the centre of dash. They are tiny and were partly corroded and partly already burnt. Solution was simple - cut the out and solder the wires previously connected through the header directly. No more problems. "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo Smile
Post #735215 17th Oct 2018 7:30am
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PaulMc



Member Since: 17 Jan 2009
Location: Kent
Posts: 486

United Kingdom 1989 Defender 110 2.5 TD HT Arles Blue
Re: Bulk Head fuse holder
tyrannosauROSS wrote:
There was someone on here a little while ago that replaced his bulkhead fuse holders. I think his were corroded/melted and he managed to source a replacement.

Can anyone remember this post? or point me to the part number. I want to install new, un-corroded ones.

Thanks
Ross



A complete TD5/TDCi fuse block and terminals kit can be bought from Autosparks -

10 Way Blade Fuse Box


Click image to enlarge



You don't need the lid or the aluminium mounting plate, but in the rest of the kit are the same Lear components used on the Defender.

. Paul.
1989 Arles Blue 2.5TD 110 Hardtop
1999 Epsom Green Discovery II 4.0 V8i 'XS'
Post #735270 17th Oct 2018 12:20pm
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landy andy



Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5416

2006 Defender 110 Td5 USW Zermatt Silver
You don’t know if you can just the metal terminals do you Paul? I just need one.

Andy.
Post #735298 17th Oct 2018 1:58pm
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PaulMc



Member Since: 17 Jan 2009
Location: Kent
Posts: 486

United Kingdom 1989 Defender 110 2.5 TD HT Arles Blue
Autosparks don't list them separately - however, they may do, if you call them.

If not, I have compatible terminals, details here -

http://www.defender2.net/forum/post145671.html#145671


. Paul.
1989 Arles Blue 2.5TD 110 Hardtop
1999 Epsom Green Discovery II 4.0 V8i 'XS'
Post #735300 17th Oct 2018 2:09pm
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landy andy



Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5416

2006 Defender 110 Td5 USW Zermatt Silver
Thumbs Up
Post #735302 17th Oct 2018 2:13pm
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