Engine/Transmission (1994 - 1998) Headlights fluctuating

[RacerBiggie]

OK, I've gone to the archives and found that the grid heater may cause the lights to go dim and then return to normal when the vehicle is cold. I've watched the voltage gauge move in sync with this as well. The problem is that this is still happening after the truck is warmed up. I drove across the whole state of OH with this going on wondering when and if they were going to go out altogether. Any suggestions? Thanks ahead of time.

 

[rjones]

Maybe the grid solinoids are starting to go..... might want to check into that... . Rick

 

[JJW_ND]

I had the same problem and it ended up being the solinoid assembly on the drivers side fender that controls the heater grids. I would check to make sure all the small bolts and fasteners on this assemble are tight.



To keep from replacing good parts, when it is happening, pull over and loosen/remove one or bother of the two large wires that bolt to the heater grid studs directly on top of the intake. I would have something with the fasten these in place to prevent the metal conectors (now exposed) on the wire feed ends from touching anything as if the solinoid is truely energizing these wire it would be messy to have the ground on anything. If this solves the probelm it is most likely the solinoids on the fender. If you take the solinoid assemble off and shake it you migh (should if shot) here a rattle from the failed side. There are two solinoids in the assembly. Have to be it as a set.



Not sure if Cummins has this as a part. I believe is was some $90 or so.





jjw

ND

 

[RacerBiggie]

Thanks guys, I'll do some checking tonight.

 

[erempel]

I had a problem with my headlights flickering, bad enough they would almost go out, and it didn't matter if the truck was warm or cold. It started out barely noticable and continued to get worse and worse. It always happened when I would hit a bump in the road.



It ended up being a ground connection. I am not positive witch one it was as I cleand and reconnected (with anti-corrosion grease) all of them that I could find. These included the battery cabels and chassis grounds. My guess was that it was the one that ran down by the radiator on the drivers side and connected to the frame about 8" back from the front bumper.



If your amp gauge does not fluctuate when this happens this could also by your problem.



Good luck

 

[Turbo Thom]

Mine did the same thing and like y'all I just it was the grid heater. Then the lights would go out and I would have to fiddle with the light switch and they would stay on. I had the recall done about 2 years ago on the switch. Last week I had some seals replaced and the light also. Along with a new clutch. Problem solved. The connections inside the swich are not the best.



. . Preston. .

 

[WDaniels]

RacerBiggie,

I just had the same problem last Sat. My lights had been flickering and I thought that it was the heater grid or ground, then going down the road they just went out totally and would not come back on until I wiggled the headlight knob. Depending when your truck was made there is a service bulletin on the truck for the headlight switch connector melting. I checked mine and the large solid green wire which is the headlight wire had melted the housing it was in and discoloured the spade plug on the back of the switch. I had to replace the entire switch and connector. It is easy and it fixed my problem. One thing, when or if you buy the switch assy use the heat shrink that comes with the assy. When it shrinks enough it releases a glue to cover the solder joint and seals out moisture. Hope you find the problem.

WD

 

[BWilson]

I had the same problem but it was my solenoids. When I finally got around to checking it, the wires were so hot it melted the plastic covers over the grid heater connections. Just grab a wire after it has been running a bit. Theyshouldn't be plastic melting hot!!!!



Good luck, let us know what it was.

 

[BHaner]

grid heater

I was having the same problem with the lights flickering... . got to the point the gague would dip below 14 and the the gen light would come on... . Then all would reset and be fine. I unhooked the two wites from the solenoids to the drivers side battery... Problem is gone. Do I need new solenoids or is there something else to look at... like a relay or ... ?

 

[BWilson]

Chances are it's the relays.....

 

[fest3er]

Originally posted by BWilson

Chances are it's the relays.....

If the headlights and dash lights flicker in unison (at night), and the flickering varies with the road's roughness, it's most likely the relays. Check out http://home.adelphia.net/~npmrphy/relay.pdf for better-than-OEM relay replacements. It's been around a year now and I still have no problems with them, where-as the OEM replacement relays only lasted about a year.



Fest3er