2nd Gen Non-Engine/Transmission Headlight Issue: Low Beam Quit Working Intermittently

[EthanWhite]

Hi Everyone: Having an issue with my headlights. Backstory:

I replaced my factory switch due to it melting on me a couple years ago. The plug and pigtail of wires was badly distorted but I have affixed it to a new switch. It has been installed for a couple of years.

Recently while on a trip, I stopped for fuel and shut off the lights. Upon continuation, the low beams would not come back on (holding the column dimmer switch depressed for hi beams allowed me to find a place to pull over) so the high beams and low beams do not work when the headlight switch is on (just the park lights -- again you can hold the dimmer back to get hi beams but they do not stay on). I let the switch cool down for a bit and was able to get the lights working again (no smell of overheating either mind you)

The other morning in temps about 10 degress out, the headlights did not work after warming the truck up. I couldn't get them to work. I will pull the bezel today and check the connections.


They seem to come and go with little rhyme or reason. Does anyone have a suggestion? The truck is worthless to me when the lights can't be counted upon to work flawlessly.

I should mention the truck is a 98.5 24v. I replaced the headlight switch with an Echlin from Napa.

 

[BigPapa]

I replaced my factory switch due to it melting on me a couple years ago.

I would check the switch again. What you are describing is classic headlight switch issues.

 

[seafish]

Also check the OLD connector tat you reused …while the wires may not be burning up anymore, the plastic connector may be continuing to distort shape from the heat and that is moving the metal contacts inside the plastic to connect only intermittently…why not just get a new pigtail …they ARE available and NOT that expensive.

 

[petersonj]

I would take it one step further and add a couple of relays. You will gain a few benefits.

1. The approximate 8 amps that are running through your headlight switch and multi-function switch now would be reduced to about 250 milliamps as the switches would only be operating the relay coils.
2. The operating voltage at the headlight connection will be considerably higher resulting in more light on the road.
3. The headlight switch, dimmer switch, and connectors will never fail again due excessive heat from high amperage.
4. The relays can be wired in a manner that will ensure you have light on the road even if one circuit fails.

I did this to my 2002 truck right after I purchased it new (now with 245,000 miles) and I a have never replaced any headlight circuit components.

Of course, you can do all of this in your spare time.

- John

 

[BigPapa]

Both excellent tips. I have done both myself.

 

[GAmes]

Problems seem to be cyclic, headlights are the current one it seems. Search is your friend.
https://www.turbodieselregister.com/threads/253409-Head-Lights-gone-wacko