headlight motor issues...
 

Okay, my headlight motor stopped working recently. It used to be that it would work fine about 4/5 times, the other time you had to tap the wire going to it. (I just thought dirty connections and never got around to cleaning it.) Then a couple days after it got a little worse, it stopped working completely. I know the motor is good, and I just got a new relay. We checked for power to the fuse and there was none. What things could have gone bad?

Try to move the connector just near the relay. I have the same problem on a 1976 924 model. It was not a problem with the relay. The connections on the headligth motor are very small diameter and the plastic arround become to melt so connections are bad. It works good when the connector is maintained a little leaning and i solve the problem with a plastic electrical collar between relay and conector.
Good luck (excuse my bad english)

also, check the wires themselves for continuity, as you said that you had to tap the wire to the motor. there may be an open in one of the wires

Hey Ollie! i been fartin around here and you keep apologizing for your english. dont sweat it! is better than mine in a lot of my posts.

anyhow, i had odd headlight motor problems (would cycle up and then back down immediatly). i had to remove the motor and take off the plastic cover to clean the metal plate on the worm gear thing. it can get a bit rusty.

I've had exactly the same problem myself. The problem seems to be, as mentioned above, with the tiny connections that the relay plug into within the motor itself. I think it was AF Juvat or SoCal that informed me that the relay is supposed to be covered with a little rubber boot. Mine was / is missing. I believe that the boot probably holds the relay in place that little bit more snug. Also, of course, it helps keep the **** out of the connections. I tried to buy a new one on its own but was told it was unavailable for the early motor.

Anyway ... I found that the headlights would pop up (switch on) if I slammed the door, drove over a pothole, slapped the wing, slammed the bonnet, kicked a tyre ...

I removed the rubber boot off the motor body and had a good look around at the soldered joints but couldn't see any fractures, dry joints or anything loose causing shorts. Disappointed I reassembled the lot and replaced it on the car.

In the end I got a dental descaler (like a tiny hockey stick for cleaning crap out from under the gumline of yer gob) and pared it down even smaller with a file until I could get it right down in the connections to give it a bloody good clean. Then I took a tiny (tiny tiny) screwdriver and lightly pinched down on the ledges of each female connection slot so they'd grip tighter on the blades of the relay. Finally I got a large rubber o ring - off a plumbing fitting and strapped the relay in tight against the motor. Don't forget to disconnect the battery whilst fiddling with the connections.

Instantly fixed!

But none of that would explain not having power to the fuse under the dash would it? We've already opened the motor and made sure everything inside is clean, it works. We checked it by hooking it to the battery. and we cleaned the connections/made the plug fit tighter...nothing.

Hmm. How far downline from the fuse have you been able to check? Have you checked the individual prongs that the fuse sit in? These often seem to overheat and lose their spring. Often times the fuse becomes corroded - even though it looks fine on a cursorary inspection. How far down the feed can you get current flow when earthed? Sounds daft but have you cleaned the fuse conns. and run a meter over them? Break in the line further down?

replace your relay for $25, then see if problem goes away.

The trigger power to start the headlight motor comes from the light switch. This closes the relay on the motor. Fuse #1, 16 amps, is for the head light motor.

We already replaced the relay and the fuse is good. The switch works to turn the lights on and off, but there is no power going to the headlight motor fuse. If part of the switch is bad would it keel power from going to the fuse?

Main buss #30 from battery powers the headlight motor. You need to check both sides of the fuse holder to ground. You may have a bad fuse and not realize it.

Here is the head light motor schematic for the early 944's.

http://www.pelicanparts.com/944/elec...944_84_2_1.jpg



Mostly the same for the later 944's with some fuse number changes.

The power to the fuse comes from section 4 (IV) line 9. You will find a return pointer to section 2 (II) line 11.