Strange Electrical/Light Problem

[gbelous]

I have a couple questions / problems...

First is this...after driving roughly an hour with the headlights on, the **** in the dash heats up...almost to the point that the metal prong that holds the plastic **** on is so hot it can burn you. After the hour if I hit a bump just right the headlights and interior lights go out. Which is not much fun when driving at night. Does anyone know what is causing this and how to fix this?

Second...there constantly seems to be a slight flicker of the headlights and interior lights. I already replaced the alternator and it did not fix this. The battery is good, so what is causing this? Is it normal or is some wiring screwed up?
Any help would be great...thank you!!!

 

[frosho]

Replace that headlamp switch ASAP!! The contacts inside have deteriorated and are generating resistance. Resistance = heat, heat = fire, REPLACE THE SWITCH!

I bet that'll solve most if not all of your issues.

 

[gbelous]

alright, ill stop and pick one up for this weekend...thanks!

 

[Storm-Chaser]

I do know that there is/was a specific pigtail kit for this problem (headlamp switch failing and melting the plastic harness connector, depending how long the problem has been present). I believe that there was a Safety recall for this problem, as well.

Replace the switch, check the gray plastic connector for heat-related damage and replace if necessary. If you need the part number to order a replacement connector or pigtail kit, just ask.

 

[Rockledge]

There was a safety recall for '93-'94 on account of the switches burning up, but it happens to other years, as well.

Check out: http://www.shoforum.com/showthread.php?t=80787

 

[gbelous]

Okay, so I just need this...
http://www.partsamerica.com/productdetail.aspx?MfrCode=BOR&MfrPartNumber=S2045&PartType=408&PTSet=A

unless the harness is melted then I need this...
http://www.autozone.com/selectedZip...itialvehicleId,1957504/shopping/selectZip.htm

is this correct?
this isn't a recall i can just ask the ford service people to do, is it?

 

[gbelous]

How much of the dash do i have to take apart to get the switch out?

 

[smokin joe]

Take the 2 screws out that are on the top of the gauge cluster surround. And then take the steering column cover off(4 screws I think). And once thats off you will see 2 more screws on the left (behind blinker) and right of the column. Then grab a hold of the whole black piece (easiest to grab top above gauges) that holds the headlight, defrost, clock, drivers vents ect, and pull, it just kinda clips in. Once you get that pulled away you can get the headlight switch out, pull **** off, unscrew nut under ****, disconect clip, put new one in, put back together and hope its fixed

Edit here ya go



WOW old pic glad I put the black interior in

 

[gbelous]

Awesome....thank you very much, that helps a lot.

 

[smokin joe]

No problem glad I could help

 

[gbelous]

Took it apart and the harness was all melted...got the switch from Advance Auto but their harness as well as the one from Autozone didn't match. So now I have to go thru Ford for $45 for just the harness. Very frustrating!
Just figured I would share / vent.

 

[Storm-Chaser]

Was the "harness" melted, or just the gray harness connector?

You can remove each harness wire-lead from the melted connector and re-insert into the new connector. It sounds like they're trying to sell you the entire pigtail kit, which you do not need unless the insulation for some of the wire-leads has melted or burned. Even then, you can get the specific wire-leads from a salvage yard Taurus/Sable, as each wire is color-coded. You might even get lucky and find a good headlamp switch connector while you're at it . . . .


:wave:

 

[gbelous]

That would have been a good idea...lol. but I already picked up the harness and switch and installed it saturday. it was pretty easy. I had to use the new harness and wires it came with because the old one was pretty melted and I didn't even think of salvaging the connectors, they were in there pretty good thou. So it's over and done with now and I can finally drive at night again.
Thanks for the help!

 

[Storm-Chaser]

I've seen the headlamp switch connector melted to the point that the connector had to be literally cut, piece-by-piece, away from each of the headlamp harness lead-wires. And despite the fact that the connector was that badly melted, none of the harness insulation for any of the harness-leads, nor any of the harness-wire terminals were damaged.


Oh, and the connector [*]without[*] the harness-leads is less than $6.00 F*** dealer parts counter price!

 

[gbelous]

yea...dealer counter parts are a joke for how much they charge...oh well..next time i guess.