High beams only work if I hold back the stalk. Just Replace stalk ?

[sugarwood]

I am going to replace the steering wheel bushing (PEL-ML-STR), so I thought to address the high beams while the steering wheel is off.

Low beams work correctly.

When I pull the stalk towards me to "flash to pass", the high beams work properly.

But, when I push the stalk away from me, the stalk firmly clicks into place, but the lights totally go dark. Not even low beams are on.


I'd like to get both done at once. With shipping taking a week, I'd prefer to order the new stalk unless there's a high probability the original is easy to fix.

Can my stalk typically be fixed, or should I just order part number 911-613-305-01-M78 for $125 (SWF) and be prepared to replace it?

Oh, PO did an H4 upgrade, but I'm not sure if the tech installed relays. Where is the best place to look?
If I don't see them, should I just order the Pelican relay kit? JWST-911-HLPR. That has quality relays?
The relays can be done indep. of the steering wheel job, but I'll include them in this order.

UPDATE:
I ended up replacing the turn signal stalk for $125.
My brights now can stay on!
It took a while, but was doable for the beginner.

1. Take off steering wheel.
2. Take apart clamshell housing.
3. Remove old turn signal stalk.
4. Remove headlight switch for easier wire transfer
5. Unclip all turn signal connections.
6. Snake out old turn signal.
7. Feed wires from new turn signal
8. Make all connections
9. Reinstall everything

There are 3 wire harnesses that feed into the headlight switch.


I wrote them all down, in case someone ever mixes something up.
This is from a '86 coupe

Turn signal stalk harness
White/black -> 56
Grey/black -> 58L (inside)
Grey/red -> 58R (inside)
Red/white -> 75

Plug Prong harness
Grey/black -> 58L (outside)
Grey/red -> 58R (outside)
Grey solid -> 58 (between 56 & 30)
Grey/white -> N
White/green -> 57
Black/blue -> 58a

Electrical tape wrapped harness
Red/white -> 75
Red solid -> 30
Blue/black & Black/blue -> 58a

[steely]

if you are looking for relays for the headlights, there is a kit here that is fine. JWST-911-HLPR
As for the stalk fix, I think there may be a fix. I say that only because my hi beams turn on when the turn signal returns home - and there is a fix for that. And my stalk is only a few years old. Perhaps the h-beams can be fixed in a similar manner that someone can share / point to.

[chrisg252]

Here's a link to a repair thread. The switch can be fixed.

turn signal switch quick fix pictures

[911s55]

Disconnect the ground at the battery while fiddling about or you might be buying a new switch.

[kidrock]

you can either bend the contacts in the old switch, or buy a new one.

[wildturkey]

I had a similar problem. My High beams would flick on over bumps. The place where I buy some of my parts told me I had to replace the switch.

On removing the switch and a good look inside. I discovered the contacts could not only be accessed but manipulated to gain the correct clearances.

A good inspection and a bit of common sense will save you some $ on this.

[sugarwood]

The switch sounds like it fails in two ways. One is with bad contacts. The other is with a failed toggle "clicker" action. My high beam stalk doesn't click. Is that a different issue than the fixable bent contact point issue?

[VW_NUTT]

I'm just curious. Are you pushing the stock forward for high beam or pulling back expecting it to be like many American cars are?

[911s55]

Read the attached link, it should be clear.
It is a mechanical switch that makes electrical contact, so if it is not right mechanically then it can't function, and yes the clicks are/were related to proper function. If you do get it to work it might not feel or sound as it did previously.

[targa80]

If a relay kit was installed with the H4's then it would most likely be in the frunk right near fuse 1 on the fuse panel since the high beam low beams are on fuses 5 thru 8. When I did mine I used the Bosch round relay connectors and have them hanging right next to the cover near fuse 1. They can either sit right behind the carpet or be pulled out on top of the carpet.

[sugarwood]

Here is a clarification. When I pull the stalk towards me to "flash to pass", the high beams work properly.

But, when I push the stalk away from me, the stalk firmly clicks into place, but the lights totally go dark. Not even low beams are on.

[na2ub]

Clean/adjust the contacts. A little fine sandpaper will remove any corrosion and they will be like new.

[targa80]

Originally Posted by sugarwood

Here is a clarification. When I pull the stalk towards me to "flash to pass", the high beams work properly.

But, when I push the stalk away from me, the stalk firmly clicks into place, but the lights totally go dark. Not even low beams are on.

It is normal for the low beams to go out when you select the high beams with the directional stalk. This would mean that the stalk is not making contact with the high beam contact when you select them to be on. It is also possible that if the relays were installed they were not wired in correctly. The schematic below is not pretty but it was what I did to add the relays for the higher wattage H4 lamps.

[targa80]

use this drawing because I did not show were I cut the circuit. this one has the cuts.

[sugarwood]

I'll hold of on buying a new stalk. When I do the bushing, I'll try to remove the stalk and clean the contacts.

But, if the shop incorrectly wired the high beams, I'll probably have to take it to a pro. I doubt I can debug and correct a professionals work. That wiring diagram is beyond my pay grade. If there were pictures and directions, I could follow that.

This gives me pause to attempt the relay project. I've only read how simple it is, but that diagram is Greek to me.

[TheSt|G]

Originally Posted by sugarwood

This gives me pause to attempt the relay project. I've only read how simple it is, but that diagram is Greek to me.

The relay project is quite simply:

1. Unplug battery
2. Unplug wires from appropriate spot on fuse panel
3. Plug in Relay
4. Plug in battery

Vast majority of the time will be spent fishing the relay wires behind the fuse panel for a clean install.

[rothaus]

I have the same issue with the Hi-beam going on when the turning signal switch returns. Something to fix.

However, here is a picture how I did the H4 relays install.



Here is the complete install, with the information what parts are needed.

Engelbert's Garage - Cars - Autocross - Car Racing and Porsches

Cheers
Engelbert

[blpetry]

Here's a link to a repair thread. The switch can be fixed.



turn signal switch quick fix pictures

Mine did the exact same thing, fixed in 10 minutes using the above info.

[sugarwood]

I'd like to examine the cross section of the high and low beam contacts, like in the photos.

Do I just remove each screw on both sides? Then what? Pull the casing apart?
Strange fastener. I wonder how the screw holds the top and bottom casing together.

[sugarwood]

I looked for relays, and didn't see anything obvious.
I see some wiring tucked underneath the large gas tank tube, but do not know it that's all stock.

My (+) battery terminal has 3 main connected to it.
1 thick cable that probably goes to the starter.
1 thin black cable.
1 harness of smaller red cables.

Are all 3 part of the OEM configuration?
Or could one of these be a direct power source for relay enabled headlights ?