Think I amy have found my headlight problem... ideas?

[Leland Pate]

Well, last night i braved the freezing weather and started tracking down the problem with my non working headlights.
Here's what I've found.
The interior lights, parking lights and turn signals work properly.

I removed the headlight switch from the dash and low and behold, I found one badly melted wire. After cross referencing my wiring diagram, I now know that this wire (colored black and white) leads to the turn signal stalk.
I then removed the steering wheel and plasitc covers to gain access to the signal/beam selector stalk. It is kind of nasty with quite a bit of lint buildup, but I can't see anything obviously wrong with it. I did take a few pictures last night as well as scanning the wiring diagram I'm refering to onto a disk, but somewhere between home and work the disk decided to crap its pants... so I'll have to take more pictures today.

I guess it would be safe to assume that the blinker stalk shorted out?

What do you guys think? When I move the switch from low beam to high beam, the metallic tabs don't move... but i'm not sure how to figure out if the stalk is working properly by simple visual inspection.
Are there any tests I can run???


Thanks and sorry for the lack of pictures...

[Jdub]

Leland:

Take a look at this post (Brights problem) and note the pic provided that shows the signal switch and the relation of the solid bar to the three thin copper strips that control the hi and lo beam operation. What is happening is that the current draw and age has caused the thicker metal actuating piece to bend over time: heat and age - the two conspire to mangle the action. You can take away the heat with the relays and remove the aging by bengind the bar back in place.

Take a hard look at the pic and take a look at your switch. What you will do is use two needlenose pliers or equiv to gently bend the right side of the metal bar up a bit so that you return the switch to its original working mechanical state. Once you do this, you will no longer have the contacts on the copper strips touching where they shouldn't be.

Also, of course, put the kit in.

John

EDIT: Now is the time to get some plastic polish on the gauges or turn them if you are so inclinded - great access with steering wheel off. Also, I cleaned the bejabbers out of the plastic pieces and the dash, attempted to regrease the switches, and removed the Momo padding off the steering wheel in favor of the brushed black metal look underneath and the use of a Porsche center crest horn button. Also bent the signal return copper piece and put a bit of dielectric on it.

[nostatic]

When mine smoked, the symptoms were that interior and turn signals were fine, but the headlights defaulted to high beam, and would only switch to low beam when you pulled the lever back about 7/8's of the way. Also, the rheostat on the light switch didn't work (couldn't dim the dash lights). Replaced the headlight and turn signal/high beam switches and installed Sucro's relay kit. Rumor has it you can sometimes repair the high beam switch, but I opted for replace and protect.

[Leland Pate]

Ok, now I'm pretty sure I've got it.
A friend and I tracked down the fault with the aid of the factory wiring diagrams. We found that power was getting all the way up into the turn signal stalk...and that's where it stopped. (Guess that's why no fuses blew) Also, the bright lights work if you pull the stalk "back", like to flash someone... but the high and low beams don't work. So, it looks like I need a new one. I just ordered one from Pelican, as well as a few HP relays to keep this from ever happening again.

I'm going to Yakima, WA in about 15 minutes for the week so if any of you locals wanna meet up for a beer just give me a call at 208-794-6072.

By the time I get back, I should have the switch in the mail and can get my car running again.


Thanks for the help everyone!

[Leland Pate]

I also need someone to keep "bumping" this thread at least for today...


I know Yakima isn't that far from the Seattle area... you guys.... come on down!!!!