Ducato headlight again!

[Badknee]

I’ve posted about losing my headlights before but this time in heavy rain I lost the lot, side and head.
2006 no airbag.
Cowels off, wheel off, unplug electrics.

Full cassette, lights, wipers the lot.
Take out the six little screws and split but take photograghs so you know what goes where

Notice no stalks? They HAVE to come off to put it all back together. Two pegs on each side.

WD40 for cleaning purposes only.

See the big white assembly? Look underneath that and there’s the problem. It’s a slide and it’s not making a good contact.

The contact under my thumb has been cleaned and replaced (sidelights) the one on the right of my thumb is dirty and burnt. The contact has a spring underneath it to push it out and make a good contact.
On the left of the recess it had burnt the nylon and it was holding the contact down and breaking contact... no lights.
I shaved it away with a craft knife to make way for the contact to slide once more.

If you blow this picture up you can see the contact and spring. I cleaned everything up and stretched the spring slightly and put everything back together BUT I had to do it more than once the first time
Black items all wiper related, white items lights and indicators

DO NOT PLUG THE STALKS BACK IN THEIR SOCKETS BEFORE TESTING

Put everything back and stick your finger in the socket for the stalk

When your happy line the lights pin on the stalk and push it in till it clicks.

Put it on the steering column and plug wiring loom plugs back in, tighten clamp, ignition on, and check everything works.

Replace cowel and steering wheel.

I did this in the pissing rain in the arse end of nowhere in Spain this morning so it can be done.

Good luck.

 

[Badknee]

Of course you could just rip it out, chuck it in the bin and fit a new one....................... but not when it happens in the arse end of nowhere

 

[DBK]

I’ve posted about losing my headlights before but this time in heavy rain I lost the lot, side and head.
2006 no airbag.
Cowels off, wheel off, unplug electrics.

View attachment 266040

Full cassette, lights, wipers the lot.
Take out the six little screws and split but take photograghs so you know what goes where

View attachment 266046

Notice no stalks? They HAVE to come off to put it all back together. Two pegs on each side.

WD40 for cleaning purposes only.
View attachment 266043

See the big white assembly? Look underneath that and there’s the problem. It’s a slide and it’s not making a good contact.

View attachment 266045

The contact under my thumb has been cleaned and replaced (sidelights) the one on the right of my thumb is dirty and burnt. The contact has a spring underneath it to push it out and make a good contact.
On the left of the recess it had burnt the nylon and it was holding the contact down and breaking contact... no lights.
I shaved it away with a craft knife to make way for the contact to slide once more.



View attachment 266042

If you blow this picture up you can see the contact and spring. I cleaned everything up and stretched the spring slightly and put everything back together BUT I had to do it more than once the first time
Black items all wiper related, white items lights and indicators

View attachment 266041

DO NOT PLUG THE STALKS BACK IN THEIR SOCKETS BEFORE TESTING

Put everything back and stick your finger in the socket for the stalk

When your happy line the lights pin on the stalk and push it in till it clicks.

Put it on the steering column and plug wiring loom plugs back in, tighten clamp, ignition on, and check everything works.

Replace cowel and steering wheel.

I did this in the pissing rain in the arse end of nowhere in Spain this morning so it can be done.

Good luck.

Impressive, and well done.

Did you fill the cassette before or after the job. So to speak.

 

[mikebeaches]

Blimey!

I'm impressed, but not something I'd care to tackle.

 

[Badknee]

Impressive, and well done.

Did you fill the cassette before or after the job. So to speak.

No I filled that when @90kmh in the pissing rain on a single carriageway road the lights wouldnt work.

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[golly]

Well done that man

 

[Lenny HB]

Brave man well done.

 

[Ismbardbrunel]

Well done for that, makes me wonder now, i have a ducato 05, when activating my side lights, my mains come on (don't mean the main beam), as well, turn the switch up a notch, nothing happens as they're already on..
When messing with the switch, i can turn on the sidelight and sometimes, just for a split second, the main lights come on just after the sidelights.....is this a problem with ducato's ?

 

[Badknee]

Well done for that, makes me wonder now, i have a ducato 05, when activating my side lights, my mains come on (don't mean the main beam), as well, turn the switch up a notch, nothing happens as they're already on..
When messing with the switch, i can turn on the sidelight and sometimes, just for a split second, the main lights come on just after the sidelights.....is this a problem with ducato's ?

Yes @Ismbardbrunel It was with mine and is with yours. You will lose them in time I think.

That tiny little contact bar on the kitchen towel turns the side then heads on.

It clips into a holder under the square assembly and moves across as you turn the stalk. Off, side, head

I’ve half built the cassette on the light side but you can still see the wiper side on the left.
Centre left are four contacts. Off, intermittent, speed 1, speed 2
The upright contacts are for wash wipe, one side is wash the other wipe four times.

The circuit board controls all this.

 

[maison]

I wouldn’t dare to try such a repair!

On a bad day it takes me all my time to find the ignition switch with the key!

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[Badknee]

I wouldn’t dare to try such a repair!

On a bad day it takes me all my time to find the ignition switch with the key!

I did it the first time on a large table covered with a sheet and my better half standing by. Four eyes are better that two when bits shoot off all over the place.
Once on the table and the six screws removed I then unclipped the two halves of the cassette and the whole bloody lot fell apart, I kid you not!
Nothing shot off, no springs, no clips, it just fell apart. I was mortified

 

[Figaro]

I'm not sure I'd even know how to remove the steering wheel !
Well done for that, I take it everything worked ok afterwards.

 

[Badknee]

I'm not sure I'd even know how to remove the steering wheel !
Well done for that, I take it everything worked ok afterwards.

Yes thanks, it seems that the little contact for the lights was stuck. I cleaned it’s “housing” with a craft knife to give it more space to move in and out under the spring load.

 

[MillieMoocher]

No words for the admiration of your abilities!

 

[Ingwe]

Way, way beyond my abilities! Well done.

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[jockaneezer]

I did similar when the indicator stalk on my Renault Master stopped working, but the repair only lasted a couple of weeks so I got another stalk assembly off a Renault Scenic from the breakers which just plugged straight in. About a month later I went to toot the horn at a friend who was walking along the road, only to find that the horn isn't on a Scenic's indicator stalk !

 

[Badknee]

Oh don’t. I once many moons ago tooted my horn to show my appreciation of a ladies very nice rear elevation

And the bloody horn stuck on!

Oops.