4kq headlight switch woes...

[Huw Powell]

> My instrument lights and all the outside lights other than the headlights
> have been intermittent lately on my '86 4kq.  Jiggling the headlight switch
> usually "cures" the intermittent problem, but did not this morning.
>
> I managed to get the headlight switch out from the instrument bezel, and in
> the process, the white wire pulled out from its crimp.  The white wire is
> for the headlights, I concluded with some experimentation -- so the
> intermittent with all the other lights is still a problem.  In disconnecting
> the headlight switch from the plastic block connector, the two gray wires
> also pulled out of the plastic block.  These gray wires may be for the
> instrument lights, as some of the gray wires lead to the instrument light
> brightness control.  Not sure where the parking lights wire into this
> switch.  Kind of wondering if bad crimps or a bad switch is the problem.
>
> Has anyone managed to get the spade connectors out of the plastic block to
> repair them?  How?

Let's see if I can remember this stuff... that switch has a lot of wires
going to it.

There is an "ignition on" 12v source and ground to run the light in the
switch.

There is a big wire from the battery, which is switched to the 3 small
terminals in park and headlight mode.  One terminal each for dash lights
and some running lights, for the left side running lights, and for the
right side running lights.

There should also be a big "LRR" wire, ie, ignition on but not while
starting, which is switched in the headlight mode and goes next to the
dip switch on the column.

The best overall fix consists of a few stages.

1st, get a good switch, or at least one that consistently makes the
headlight connection and at least one running light connection.

Then, relay your high and low beam circuits so the bulbs are powered
fromt he battery or alternator to remove that high current load from the
switch.

Then, relay the running light circuits (this can be set up right behind
the switch), from one of the running light terminals, to remove that
load (those little bulbs add up!).

use whatever means at your disposal to make the switch connections - a
used, unmelted socket with 6" of wire on it is nice, but you can just
use crimp terminals where necessary if that's all you have.

--
Huw Powell

http://www.humanspeakers.com/

http://www.humanthoughts.org/