Main Light Switch / Headlights Issue - Defender Source
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  #1  
Old January 13th, 2015, 11:25 AM
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Main Light Switch / Headlights Issue

All of a sudden, my headlights won't go on when the main switch is in position 2. In position 1, all the parking lights, dash lights, etc. all come on as usual.

But when I switch to position 2, dash lights go off, no headlights, no parking lights.

opened the steering column nacelle, tested switch and it's ok
shorted the contacts to switch the lights on - position 1 ok, position 2 has no effect
swapped in another relay for the headlight relay, nothing
checked fuses - all ok
checked the fusible links in the engine bay - all ok

Is there something else I'm missing guys? thanks as always.
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  #2  
Old January 13th, 2015, 11:42 AM
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David Short
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dip / dim switch in the turn signal stalk is burnt out.
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  #3  
Old January 13th, 2015, 11:47 AM
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Scott T
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Quote:
Originally Posted by Firemanshort View Post
dip / dim switch in the turn signal stalk is burnt out.
Unfortunately very common. But is it the high beam/dip switch in the turn stalk, or the light switch (seen this many times, as opposed to the dip switch). When you replace it, it is HIGHLY recommended that you also install a headlamp wiring harness, that takes the load off the switch, and puts it on a the larger gauge wiring and relays of the harness (relegating your stalk switch to the load of clicking the relays on and off)..

http://www.defendersource.com/faq/Light/LightHead.html

http://www.defendersource.com/forum/...ad.php?t=14715
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  #4  
Old January 13th, 2015, 12:11 PM
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Quote:
Originally Posted by Firemanshort View Post
dip / dim switch in the turn signal stalk is burnt out.
I thought about this as a possibility. thanks.

------ Follow up post added January 13th, 2015 12:12 PM ------

Quote:
Originally Posted by LRNAD90 View Post
Unfortunately very common. But is it the high beam/dip switch in the turn stalk, or the light switch (seen this many times, as opposed to the dip switch). When you replace it, it is HIGHLY recommended that you also install a headlamp wiring harness, that takes the load off the switch, and puts it on a the larger gauge wiring and relays of the harness (relegating your stalk switch to the load of clicking the relays on and off)..

http://www.defendersource.com/faq/Light/LightHead.html

http://www.defendersource.com/forum/...ad.php?t=14715
Thanks Scott. Extremely helpful. I was doing some searching but just didn't turn this up. I appreciate the source too for the harness.
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  #5  
Old January 14th, 2015, 04:54 PM
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any other suggestions guys?

I changed out the turn signal/horn/dip stalk, and same thing - parking lights and dash come on when main light switch is in the number 1 position. but switching it to the number 2 position turns off dash lights and no headlights.

Flashing (high beams) on the turn stalk works, just as with the old turning stalk.

Any other suggestions I should try?
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  #6  
Old January 14th, 2015, 04:58 PM
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Peter
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Had a similar situation in my RRC, root cause turned out to be a bad common ground.
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  #7  
Old January 14th, 2015, 05:39 PM
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I bet it's the main light switch. I'm going to do a test...
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  #8  
Old January 14th, 2015, 05:42 PM
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I had this exact same thing happen to me on the way to work the other morning, and it was the switch. If you take apart the switch you can see where it hits the contacts. The contact had completely fallen out of the switch (probably melted the plastic). I had a spare switch I put it, but was also able to repair the original to keep as a spare.
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  #9  
Old January 14th, 2015, 05:53 PM
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Amit Likhyani
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glad I saw this. My high beams no longer work. I'll check the switch and upgrade to a relay once I determine that's the problem.
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  #10  
Old January 14th, 2015, 06:48 PM
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Quote:
Originally Posted by defender1844 View Post
glad I saw this. My high beams no longer work. I'll check the switch and upgrade to a relay once I determine that's the problem.
Yours probably isn't the main headlamp switch.
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  #11  
Old January 14th, 2015, 07:07 PM
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Amit, I don't think your problem is the main light switch either.

My problem was the main light switch all along.

When I initially took off the connector, I made the mistake of assuming the 3-conductor main switch was an SPDT switch. This was not the case when I re-read the electrical library book. In the book, it says, "...position 2 additionally switches on the headlights." So "additionally" was the clue that this was not an SPDT switch.

Instead, the switch flows power from position 1 to position 2 ALSO, off of the brown wire. So upon re-testing, there was no continuity on the switch from brown to position 2. And to confirm, I pulled back the wire sheathing on the switch, shorted the contacts on brown to position 1, then from position 1 to 2 and bingo - headlights on.

So have to order a new main light switch, then install that and the ARB relay setup.

I swear, when I get to tearing down my 90, I'm wiring in solid-state relays and wiring up my own harnesses, my own bus systems, etc. etc.
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