Headlight switch and wiring
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More Turbo
Joined: Jun 2009
Posts: 510
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From: South Park, Colorado
Headlight switch and wiring
I'm having some electrical issues with my truck (85' F350) that I believe are associated with the headlight switch and wiring. I have headlights, intermittent running and tail lights. The wiring off of the headlight switch is brittle and discolored, I thought I even noticed some smoke from under the dash with the lights on
.
Anyway, I would like to replace the headlight switch, associated wiring and add a relay(s) to the system as it is my understanding that all of the current flows through the switch?
My questions; is there a preferred supplier for the headlight switch? Has anybody used the headlight wiring harness/relay kits readily available, any preference as to what to use here or should I just make my own?
.Anyway, I would like to replace the headlight switch, associated wiring and add a relay(s) to the system as it is my understanding that all of the current flows through the switch?
My questions; is there a preferred supplier for the headlight switch? Has anybody used the headlight wiring harness/relay kits readily available, any preference as to what to use here or should I just make my own?
FTE Legend
Joined: Jul 2010
Posts: 32,875
Likes: 48
From: Northeast, OK
Yes, all the current for the lights flows through the switch. And several have used the various kits and I've not heard bad things about any of them - with the possible exception that some require special relays. Seems to me LMC's was one of those, so you have to order replacement relays from them - if you ever need one, which isn't likely.
However, since your wiring is toast, literally, you may need to do some repairs as well as install the relay kit. The headlight switch might not be bad, but it easily could be as it is what usually gets hot and then heats the wires and melts the insulation. That means that the connectors might have lost their spring and, if so, won't properly grip the lug. Further, the wires frequently short to each other since the insulation melts off. I would check all that out closely before just replacing the switch and installing the relay harness.
However, since your wiring is toast, literally, you may need to do some repairs as well as install the relay kit. The headlight switch might not be bad, but it easily could be as it is what usually gets hot and then heats the wires and melts the insulation. That means that the connectors might have lost their spring and, if so, won't properly grip the lug. Further, the wires frequently short to each other since the insulation melts off. I would check all that out closely before just replacing the switch and installing the relay harness.
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More Turbo
Joined: Jun 2009
Posts: 510
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From: South Park, Colorado
Gary, Thanks for the info! I will thoroughly check all of the wiring out when I replace the switch, I'm guessing I will be replacing some or all of the wiring between the switch and new h/l harness and relay.
Would you suggest a relay for the running lights? This is on a DRW truck with a bunch of extra clearance lights.
Would you suggest a relay for the running lights? This is on a DRW truck with a bunch of extra clearance lights.
FTE Legend
Joined: Jul 2010
Posts: 32,875
Likes: 48
From: Northeast, OK
It won't be easy to replace everything between the headlight switch and the relay harness as that's part of the major wiring harness which extends from the left headlight to the right headlight. So I would just replace any wires that are damaged. Or, at least shrink-wrap them if the damage is limited to the first few inches of insulation. However, excess heat can certainly ruin the connectors as it takes the temper out of them and they won't hold the lug tightly ever after.
As for the running lights, I've not heard of anyone having trouble with that wiring. You have 5 small lights across the top of the cab? They probably pull an amp each so 5 amps total. I think a new switch, assuming yours is bad, would be sufficient. But, if you are worried it would be easier to replace the lamps with LEDs than install a relay. And at that point the current draw will be nil. Problem solved.
As for the running lights, I've not heard of anyone having trouble with that wiring. You have 5 small lights across the top of the cab? They probably pull an amp each so 5 amps total. I think a new switch, assuming yours is bad, would be sufficient. But, if you are worried it would be easier to replace the lamps with LEDs than install a relay. And at that point the current draw will be nil. Problem solved.
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More Turbo
Joined: Jun 2009
Posts: 510
Likes: 1
From: South Park, Colorado
Hopefully most of the wiring is in usable condition - I did not realize it would be difficult to replace all of it. I will dig in there and see what I find.
I'm not overly concerned about the running lights, just making sure I do not need to do anything additional with them except the new switch and verifying wiring condition.
My truck has the five clearance lights on top of the cab, markers on the front and rear of the DRW fenders and underneath the tailgate. I like the idea of using LED's in these locations. I will check into that.
I'm not overly concerned about the running lights, just making sure I do not need to do anything additional with them except the new switch and verifying wiring condition.
My truck has the five clearance lights on top of the cab, markers on the front and rear of the DRW fenders and underneath the tailgate. I like the idea of using LED's in these locations. I will check into that.
FTE Legend
Joined: Jul 2010
Posts: 32,875
Likes: 48
From: Northeast, OK
I hope the problem with the wiring is limited to the switch area. That wiring harness wasn't one of Ford's better ideas as it is extensive and wraps around everything in the dash like a snake.
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More Turbo
Joined: Jun 2009
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From: South Park, Colorado
I hope so too. I will post what I find. I will probably wait until I have the switch and relay harness on hand to dig into it, probably next weekend.
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pedant
Joined: Jan 2008
Posts: 23,576
Likes: 38
From: EXTREME southwest CT
I would buy the pigtail headlamp switch plug and do it while the switch is out.
You already know the wiring and contacts are cooked.
Pico and many others sell it.
As for the LMC harness.
I would not consider it 'great quality' but mine has never been a problem in the better part of a decade.
You already know the wiring and contacts are cooked.
Pico and many others sell it.
As for the LMC harness.
I would not consider it 'great quality' but mine has never been a problem in the better part of a decade.
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Thread Starter
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More Turbo
Joined: Jun 2009
Posts: 510
Likes: 1
From: South Park, Colorado
I would buy the pigtail headlamp switch plug and do it while the switch is out.
You already know the wiring and contacts are cooked.
Pico and many others sell it.
As for the LMC harness.
I would not consider it 'great quality' but mine has never been a problem in the better part of a decade.
You already know the wiring and contacts are cooked.
Pico and many others sell it.
As for the LMC harness.
I would not consider it 'great quality' but mine has never been a problem in the better part of a decade.
Lead Driver
Joined: Apr 2007
Posts: 5,958
Likes: 105
From: Houston
Do a search for this on ebay.
1X H4/9003 Headlight Ceramic Socket Harness Wire Relay Controller Wire Kit
Find the one by the seller wholecellerusa.
I bought mine from him on sale for $14.98 with free shipping. its made in China/Japan but its good quality and you cant buy the two relays let alone the wiring, and pigtails and fuses for $14.98.
I havent hooked it up on my '82 yet as I am not sure how I want to route the wires to make them appear OEM. Every idea I have they look obvious and just scream add on.
1X H4/9003 Headlight Ceramic Socket Harness Wire Relay Controller Wire Kit
Find the one by the seller wholecellerusa.
I bought mine from him on sale for $14.98 with free shipping. its made in China/Japan but its good quality and you cant buy the two relays let alone the wiring, and pigtails and fuses for $14.98.
I havent hooked it up on my '82 yet as I am not sure how I want to route the wires to make them appear OEM. Every idea I have they look obvious and just scream add on.
Lead Driver
Joined: Apr 2007
Posts: 5,958
Likes: 105
From: Houston
It won't be easy to replace everything between the headlight switch and the relay harness as that's part of the major wiring harness which extends from the left headlight to the right headlight. So I would just replace any wires that are damaged. Or, at least shrink-wrap them if the damage is limited to the first few inches of insulation. However, excess heat can certainly ruin the connectors as it takes the temper out of them and they won't hold the lug tightly ever after.
As for the running lights, I've not heard of anyone having trouble with that wiring. You have 5 small lights across the top of the cab? They probably pull an amp each so 5 amps total. I think a new switch, assuming yours is bad, would be sufficient. But, if you are worried it would be easier to replace the lamps with LEDs than install a relay. And at that point the current draw will be nil. Problem solved.
As for the running lights, I've not heard of anyone having trouble with that wiring. You have 5 small lights across the top of the cab? They probably pull an amp each so 5 amps total. I think a new switch, assuming yours is bad, would be sufficient. But, if you are worried it would be easier to replace the lamps with LEDs than install a relay. And at that point the current draw will be nil. Problem solved.
Thread Starter
|
More Turbo
Joined: Jun 2009
Posts: 510
Likes: 1
From: South Park, Colorado
Do a search for this on ebay.
1X H4/9003 Headlight Ceramic Socket Harness Wire Relay Controller Wire Kit
Find the one by the seller wholecellerusa.
I bought mine from him on sale for $14.98 with free shipping. its made in China/Japan but its good quality and you cant buy the two relays let alone the wiring, and pigtails and fuses for $14.98.
I havent hooked it up on my '82 yet as I am not sure how I want to route the wires to make them appear OEM. Every idea I have they look obvious and just scream add on.
1X H4/9003 Headlight Ceramic Socket Harness Wire Relay Controller Wire Kit
Find the one by the seller wholecellerusa.
I bought mine from him on sale for $14.98 with free shipping. its made in China/Japan but its good quality and you cant buy the two relays let alone the wiring, and pigtails and fuses for $14.98.
I havent hooked it up on my '82 yet as I am not sure how I want to route the wires to make them appear OEM. Every idea I have they look obvious and just scream add on.
And if LED`s are wanted let me know what kind of socket they are and I will link to some on ebay that are nice and bright. Theres a trick to knowing which LED`s are good and which ones are junk that wont even put out on full brightness the light a incadecent bulb does on low.
Lead Driver
Joined: Apr 2007
Posts: 5,958
Likes: 105
From: Houston
Thanks for the recommendation. I did find the item by the seller you recommended, $20 now, but still a good deal. I will give one a try.
Let me get all of my wiring issues worked out and then I will try the LED's. I will hit you up for some help spec'ing them out. I assume you need just the bulb number(s) I am trying to replace?
Let me get all of my wiring issues worked out and then I will try the LED's. I will hit you up for some help spec'ing them out. I assume you need just the bulb number(s) I am trying to replace?
I have a website I use that list bulb dimensions by the model number.
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