E39 - Lighter/Tray Unit

The lighter and tray is one of the smaller features within an e39 and wear varies if you are a smoker or a non-smoker, either way the lighter accessory can be a useful utility.
When used, in a conscious, (task aware) manner or not in auto-pilot, when returning the lighter and then pressing down the flap after use, the lighter should function well for many years. However, for those with heavy hands and are regulalar smokers, you will find the spring flap may fail, due to possible accessive use, this will cause the flap to eventually lock, or even cause the flap to keep flipping open, keeping the lighter exposed. A cosmetic disaster!
This is down to the spring mechanism at the back of the unit failing to engage the lever within a small groove, the mechanism is not allowing the flap to lower or raise correctly. This problem can be rectified.

I noticed, because the mechanism had been forced over a period of time, the plastic 'tracked groove' needed to be manipulated back into shape whilst pushing the flap up and down directed within the groove, slowly until the unit is working freely, without fouling up.

Note: If replacing the lighter unit, be aware it is not the standard full length. It is shorter with a thinner push-in head. The full length for this particular lighter unit is 3cm as illustrated above. The width is standard width for the standard socket.

On completing the repair, return the tray and fittings as of reverse order of dismantling. Be gentle when using the flap, as it may be a little on the stiff-side - still useable. (This can also be sparingly, lubricated with either a Vaseline or another appropriate grease).

Note: The cost of replacement can be between £5 to £35, (even more from the dealership) some may also add P&P on top of this, so do shop around. Ideally purchase a complete full lighter and tray unit, otherwise costs can be much higher for seperate items.

My unit has continued to work... after following this process.

1. The first task is to remove the tray and lighter unit by prising the lower trim from above and at the back of the tray and exposing two cross screws in each corner and removing them.
2. By lifting up the Gear Gaiter from the centre console, will allow access to two further screws under the centre console these screws will also need to be removed.
3. Once the unit has been taken out, leads will need to be
disconnected, carefully. Note: This may also be a source of positive supply to other third party electrical accessories, so check for any connections and soldering joins, before pulling the unit away - By inspecting the unit and observing how the flap works, should identify any problems arising, on identifying the problem proceed to rectiffy.