Help on replacing turnsignal/highbeam lever on 83 911

domanows · 10-20-2005, 11:18 AM

Once again I have turned what would be a simple project into a mess!

I needed to replace the turnsignal on my 83 911SC because my highbeams were toggling on and off. Please note that everything else worked and this was the only problem.

After methodically removing a single wire from the old unit and replacing it with the appropriate wire on the new unit , I have totally messed everything up!

Heres what works wrong.
1. When car is off, horn holds when headlight switch is pulled
2. When turnsignal is engaged left, both front turnsignal lights flash.

What doesn't work at all
1. Headlights
2. Turn signals
3. Horn only works by headlight switch

What kind of works
1. When car is in accessory mode and lights are turned on, rear lights and license place lights work

The only thing I didn't hook up was the brown alarm wire that was spliced into the harness that plugs directly into the car via the 5 pin connector (not the harness with the 4 wires), but I put the alarm in valet mode. Basically, I was reluctant to cut into the harness until everything was working.

Please help. I am pretty sure I connected the 4 wires coming out of the harness correctly since I traced each wire and replaced them individually, but since it is impossible to see anything under the dash I had to feel where I disconnected the wire and replace it blind.

Is there any way to get better access to the circular connector under the dash to verify colors of the wire and does anyone have the schematic for which color plugs into which blade.

Thanks,
Matt

Rot 911 · 10-20-2005, 11:52 AM

Are you sure the brown wire you didn't hook up is just for the alarm? On 911's OEM brown wires are ground wires.

john walker's workshop · 10-20-2005, 11:57 AM

the brown wire attaches to one of the lower inner screws that hold the plastic housing. a ground. to reach the light switch wires, drop the switch down so it hangs under the dash. what do you mean by "methodically removing a single wire from the old unit..."?

DW SD · 10-20-2005, 12:32 PM

I suspect John has it covered, as usual. However, this is another good instance where a picture is worth 1000 words, or more.

domanows · 10-20-2005, 01:16 PM

Thanks so much for your help.

Regarding the brown ground on the harness. I have attached that to the horn seen in image "steering_column.jpg" (image 2)

The wire spliced to the alarm can be seen on the original wire that has been modified. See "alarm_splice.jpg (image 1)

What I meant by methodically replacing one wire at a time was pulling out each of the wires from the original harness and replacing it with the same color wire on the new harness. See "confused.jpg" (image3). I could not see where I was plugging the wires into. All the connections are located behind the headlight switch on the inside of the dashboard. So by only disconnecting one at a time, I felt confident that they were plugged in right. Is there any way to gain visual access to that connector?

Is it probable that the problem is caused by hooking the wires in "confused.jpg" not being hooked up right or not actually being on the blade at all? They feel like they are on but I cannot see them.

Also, does anyone have a schematic of the thing I am plugging the wires from "confused.jpg" (image 3) in to.

Hope thats a little more clear and thanks so much for the help.

Matt

vash · vash's Garage

opps. i think that headlight switch can be installed at any position. if so, 360 degrees of confusion. dude, undo the headlight switch and push it back and down. i think you gotta see what you are doing. remove the seat if you have to. i put both harnesses next to each other, and pulled one off, and pushed the new one immediately on. once complete, i just yanked the old wires off. doing it this way, i even got the new wires to run in the original position. sorry, i dont have a wiring diagram with me (plus, i am crappy at reading them)

Nathans_Dad · Nathans_Dad's Garage

I agree with vash. When I did this project I dropped the headlight switch (the pull switch to actually turn on the lights) out and down behind the dash. Then you can actually look at it and see what's what. It's simple to do, unscrew the knob and then you have to get something that will fit into the holes in the keeper, I just used two finishing nails. It unscrews from the dash. Then you can drop the switch down (still connected to the wires) and take a good look. I have the wiring diagram from the service manual at home for you to double check your placement of the wires. Will try and scan that in when I get home. Also agree with the ground wire, that has to be screwed into the correct spot. Also, did you connect the small wire that goes to the horn pad on the wheel? If not, that might cause your horn to sound when the battery is plugged in.

domanows · 10-20-2005, 06:19 PM

Rick,

You are the man! I am going to try and unscrew my headlight switch right now. If you can scan that diagram, that would be awesome! Making those connections blind was really horrible.

Matt

domanows · 10-20-2005, 07:41 PM

OK guys, I know this sounds REALLY lame, but the headlight assembly is screwed in so tight that I cannot get it loose with Rick's two nail trick. Is there a tool I can purchase that will get me enough leverage to remove this switch?

Another stupid question, although I tryed working the retaining piece both directions, can anyone verify "lefty loosey righty tighty (counter clockwise to loosen) for me.

I felt a bare blade on the back so unless there is suppose to be an empty blade, I know I am missing one lead. I definately need to see whats going on with the back of that switch.

Matt

domanows · 10-21-2005, 03:56 PM

The headlight switch retaining nut was actually glued to the dash. Removing it was very difficult so I fabricated a little tool to put on the end of a screwdriver to get the force to remove it. Hope this helps someone else.

scottb · 10-21-2005, 03:58 PM

Snap ring pliers work. I used a Dremel to get the plastic retaining nut off, and John Walker was kind enough to supply me with a new one.

domanows · 10-25-2005, 05:19 AM

Does anyone have a picture or diagram of what the wires configuration on the head light switch is. My horn is still honking when I turn on my headlights and both front signals are blinking when I turn the the turnsignal lever left. Nothing happens when I turn it right and my lights are not going on at all.

Thanks,
Matt