When cold whilst in PARK or NEUTRAL once the key was turned the button would ignite the engine no problem. As the engine got hotter and up to running temp then with the key turned there were several times the car would not start on the button and I would have to revert to the button on the solenoid under the bonnet to start the car.
I decided the problem was either with the solenoid or the Inhibitor switch on the side of the gearbox with the BW35. Bought both and changed the solenoid first as it is the easiest to get to but the problem continued.
To get to the inhibitor switch there is an inspection panel on the left side of the gearbox tunnel under the carpet held in place by six cross headed screws. Access is good and once the four wires are removed, making a note of where they all went, the Inhibitor switch is unscrewed from the side of the gearbox.
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First thing I noticed was two opposite terminals 1 and 3 were very loose against their rivets and it only took a small twist and one of the spade connectors came away in my hand. So the problem lies in these bad connectors. I worked out that there are two terminals for the reverse lights which are opposites and two terminals for the power to the starter button which were the ones that were broken.
I had a new inhibitor switch ready to fit but when I compared the old and new they were different thread lengths and the new one had no markings to signify which terminals were for reverse or ignition button. As the old switch was broken I took it to pieces to see how it works internally. So basically there is a plunger and something inside the gear box pushes this plunger in to different depths depending on where the gear lever is. The plunger then makes an electrical connection across the terminals depending on the depth it is pushed.
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Problem is as there are no markings on the new switch to work out which terminals are 1 and 3 or 2 and 4. I can work out by putting a multi meter across the terminals and pushing the plunger which terminals work at different plunger depths but that does not help as I do not know the depth the plunger should sit at when screwed in the gearbox.
I have screwed the inhibitor switch in and have been able to set the distance so when the car is in P and N the starter button works and the car will not start in gear. Problem is at this setting the reversing lights are not working when you then put the car in R. I have tried swapping the terminals over and screwing the inhibitor switch in further so again I can start the car in P and N but still the reversing lights will not work. I know there is power there because when you jump across the terminals the reversing lights come on.
The problem lies in trying to get the inhibitor switch screwed in to the correct depth to allow the plunger to be depressed by whatever is in the gearbox to the right point that allows both the starter button and the reverse lights to work.
I gave up last week as I had a wedding the following day and as long as the car started I did not mind that the reverse lights were not working but I am going to have another go this week to set it up but would appreciate any insight or assistance.
