headlight relays
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Lead Driver
Joined: Apr 2008
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headlight relays
Hey guys, we have a new work truck and the headlights will stick on sometimes, im thinking its the relays. Anyhow, i cant find the damn things on the truck, online, or even find the owner manual let alone the relays in it.
The truck is a early 97 F-250 heavy duty, 460, e40d.
Posted in the 87-96 forum to no avail, was hoping one of you handy fellers might know.
The truck is a early 97 F-250 heavy duty, 460, e40d.
Posted in the 87-96 forum to no avail, was hoping one of you handy fellers might know.
Fleet Mechanic
Joined: Jun 2009
Posts: 1,320
Likes: 1
From: CT
I don't believe the headlights are relayed. It all runs through the headlight switch (horrible design, tends to burn the connector up, and drop the voltage a ton so you have crappy headlights). It does this on the 80-91 trucks. But, the 92-97 have a similar style switch so I'm sure its the same way. I got some wiring diagrams at home i can check. Otherwise check the under hood fuse panel if it is relayed it will be in there.
Fleet Mechanic
Joined: Jun 2009
Posts: 1,320
Likes: 1
From: CT
AIRTEX / WELLS Part # 1S2524
STANDARD MOTOR PRODUCTS Part # S607
Parts you need, can get them from rock auto. The switch and the connector ( your is probably a little burnt, mine is in my plow truck but the lights still worked fine). It does have the same older style system so no relay.
STANDARD MOTOR PRODUCTS Part # S607
Parts you need, can get them from rock auto. The switch and the connector ( your is probably a little burnt, mine is in my plow truck but the lights still worked fine). It does have the same older style system so no relay.
Logistics Pro
Joined: Sep 2007
Posts: 3,737
Likes: 179
From: Western Mass
Aune, replace the switch and the connector. I can just about guarantee that will fix your problem. As stated, the design sucks, the wiring is too small, and it overheats melting the connector, and damaging the switch.
Then do the relay mod and don't worry about it again.
If it doesn't, and your truck has one, replace the floor switch if the headlights don't dim right. All sorts of dirt and water can get in there and corrode it.
Then do the relay mod and don't worry about it again.
If it doesn't, and your truck has one, replace the floor switch if the headlights don't dim right. All sorts of dirt and water can get in there and corrode it.
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Lead Driver
Joined: Apr 2008
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Oh wow... i knew this was a problem on older trucks like my 79, i couldnt imagine they didnt add relays in there by 97.. well thanks for the info fellers i appreciate it, no wonder i couldnt find em lol
Fleet Owner
Joined: Jul 2006
Posts: 20,345
Likes: 802
From: Mi'kma'ki
if this thread doesn't fix ya up..........i dunno what to tell ya.
https://www.ford-trucks.com/forums/1...t-upgrade.html
i remember my headlight switch going did funny things too.likely your in need of a new switch and harness too.that link above will make sure you only need to do it once.
i spend way to much time on here after work.i know my way around the idi section blind folded i swear lmao.
https://www.ford-trucks.com/forums/1...t-upgrade.html
i remember my headlight switch going did funny things too.likely your in need of a new switch and harness too.that link above will make sure you only need to do it once.
i spend way to much time on here after work.i know my way around the idi section blind folded i swear lmao.
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Lead Driver
Joined: Apr 2008
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thanks man, ya i know the "real fix" as im planning on it for mine, but i think the work truck will just get a new switch and see how it goes. Ive got the relays, wire, fuses.. everything to do mine i just keep procrastonating... not a big fan of the plastic coated copper stuff... the uh whudy-a-callums... whyers...
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Logistics Pro
Joined: Sep 2007
Posts: 3,737
Likes: 179
From: Western Mass
Before you buy just the switch, look at the harness. The plastic connector on my truck and at least one of my parts trucks is seriously melted in the middle. The plastic is discolored and brown like it was about to catch fire. I replaced the switch and found the running lights didn't work, took a closer look and the wire was loose on the connector and wasn't engaging the switch. Matter of fact, I'm not even sure the headlight switch had a problem, the connector may have been the real issue.
Its easy to replace. I recommend soldering the wires and shrink wrapping the connections, but good crimped connections will work. Just do one wire at a time and match up the locations on the connector as the colors may not be the same.
Its easy to replace. I recommend soldering the wires and shrink wrapping the connections, but good crimped connections will work. Just do one wire at a time and match up the locations on the connector as the colors may not be the same.
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