H4 headlight / switch issue?

[Sizzle]

When I pull my light switch, I only get highbeams now. And when I push the light switch in just a bit (to get 'parking light mode'), the left headlight is on in a very low 'simmer' sort of mode. Is my problem in the switch up in the steering column or down at the other end near the lights? Any help would be greatly appreciated.

[Nine9six]

How about a little background...Did you just install H4's, or have they been in your car?

[silverc4s]

It's the switch in the steering column - points welded together. Do a search here on things like:
Headlight switch
Dimmer switch
Sucro Relay kit

And you will see what is needed to rectify the problem..

[DW SD]

like Bill said - in your high beam low beam selector on the stalk.

[Sizzle]

'points welded together' -- hmmmmm......come to think of it, I did smell somthing funny last week..........I'm on it. Thanks! gb

[Sizzle]

to 'Nine9six' -- the H4's were in there, and something seems a bit askew -- I can get the trim ring off just fine, but when I try to remove the 2 screws holding the rubber rings (under the metal trim) off, the screws just spin and spin and spin........not sure if I got some half-baked install or what. Looks like I'll be busy this weekend.

[silverc4s]

Originally posted by Sizzle
to 'Nine9six' -- the H4's were in there, and something seems a bit askew -- I can get the trim ring off just fine, but when I try to remove the 2 screws holding the rubber rings (under the metal trim) off, the screws just spin and spin and spin........not sure if I got some half-baked install or what. Looks like I'll be busy this weekend.

STOP ! !! DONT DO THAT !

The only screw holding the headlamp in the fender bucket is the ONE at the very bottom of the metal rim. There is a bent tab on top that it hinges on.

Those other two screws are your aiming adjusters, which you likely just dealigned an unknown amount. Hopefully yo did not run them totally out of their adjustment arms - or you are about to get a lot more intimate with your lamp systems...

[Sizzle]

thanks Bill--- slow yet thorough learning taking place here.....I successfully swapped out my dimmer switch from the stalk (no snipped wires!) and all is well -- a little black plastic thing melted and 'glued' the contacts together. Sure enuf, I tweaked the headlight alignment to hell and had to get that squared away. How do you get the headlights 'out' of the fenders? Just get under the rubber rings and give them a tug?

gb

[silverc4s]

gb,
The headlamp assembly sort of pivots on the top edge, once you have the very bottom screw loosened from the tab at the bottom of the bucket. Once it moves out even slightly at the bottom, you can just lift it off completely. Be careful, that screw and the wiring plug at the back are the ONLY things holding it from falling free, so don't let go...

NOTE: You will need to add the "Sucro Relay Kit" or those pesky contacts will reattach themselves once again...

[Sizzle]

c4s -- are my headlights pulling too much juice (thus causing the meltdown in the switch)? What does the Sucro relay kit do for the system?

[silverc4s]

Originally posted by Sizzle
c4s -- are my headlights pulling too much juice (thus causing the meltdown in the switch)? What does the Sucro relay kit do for the system?

You are exactly correct, gb.

In the standard wiring, ALL the current to the headlamps is routed through the switch on the steering column. 55 watts is 55/12 = 4.5 amps or so, too much for those little contacts to handle.

The Sucro relay kit, adds in two relays that replace the contacts in the switch as the main current carriers, and allow the switch to just handle the small current required to energize the relays.

Now you can use any wattage lamps your heart desires, and the switch will only see the small current needed for the relay.

[Sizzle]

Is the only source for that Sucro kit the guy here on the forum, 'flatsix' somthing or other? If that's the preferred route, that's ok, but I like options. Will my current contacts last even a little while? I don't want to have to eat another 125 bucks on the dimmer switch If I can avoid it. thanks for the info!

[silverc4s]

Options>

You can make the bypass circuit yourself with two Bosch type relays and some large guage wiring..
You can by the kit, with instructions from Mark Sucro..
You can clean your switch contacts, and pray they don't lock up again..
OR, you can buy a new switch and install it, which IS a beatch, I assure you...

[Sizzle]

Everything sorted out with the lights now -- the famous 'Sucro' relay kit went in like a champ (thanks Marcus), got the rubber tab / doohickeys re-attached onto the h4 headlight alignment screws; high beams cooking-away in relay-defined isolation now. Very fun project and learned a ton in the process. Thanks to the forum heads for all the help.

keeping the rubber side down,

gb

[makotosun]

I just purchased one of the relay kits from Marcus also. I have not yet installed it, but it is a really nice piece of work, and worth every bit of what he charges for it.

His site is not really that easy to find, so here is another link for those who have an interest:

!Sucro Headlight Relay

Thanks Marcus!

[FrayAdjacent911]

when I get around to it, I'll get the relay kit, or rig my own. Heck, it would probably even do better with the stock type sealed beams. Isolating the circuit is never a bad thing.

[HFR_Racer]

Thanks for the link...