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[Kevin Wood]

Just re-read and had a 'Eureka' moment. The switch has been earthed through the Grey/Yellow switch illumintion wire as well as/instead of the Brown earth wire.

Yep. That's the train of thought I was following. Probably "instead of". Failing that, the illumination feed and ground wires have been swapped over so the switch only has a ground connection when the illumination is off and the ground connection can be made through the bulb.

[05omegav6]

Probably quite easy to do when reconnecting There's not alot of space to play with unless you pull the cage out completely, hence the 6" loom/plug suggestion.
The Plod sparkies do tend to chop the wires quite close to the plugs which doesn't help either.

[Webby the Bear]

Hi guys,

Paul, not hijacking; just interested to learn more

Are we saying then that what happened with Paul's car is that the police took off his TC button to make space for something they needed and simply re-routed the wire. Hence only the probs when headlights are on?

Would it then just be a case of finding the wire and routing it back to the TC button?

Interesting thread

[P6UL K]

Well it looks like we've finally sorted it, although to do this we had to cut the illumination feed.

On the loom i got off of Rob there were the 3 feeds, Brown, Grey/Yellow and Brown/Red but on the car loom was, Brown, Grey/Yellow and Black/Red.

So we left connected: Brown - Brown, Brown/Red - Black/Red as this seems to be fine allowing the switch to operate as normal with or without the headlamps being on or off!  Haven't a clue why the illumination feed was causing issues tho...