I have a 1993 Aerostar 4.0L. The headlights will go out after about 10 mins of use. To get lights back on I have to pull back on the turn signal and use the passing lights until the regular headlights come back on. There is no rhyme or reason to when they go out or for how long. I know I saw similar problems like this discussed but for the life of me can't find them now! What should I check first?

 

kag
check put 3003davids post just 2 or three down it is on lights it may help you

 

my 91 aero used to do that, just before the blinker switch went out. the night they died I had to use rubber bands to hold the lever back in order to keep the lights on while driving.

one symptom I noticed when it all happened was that the switch didnt click clack when I switched from high beams to low beams any more.

pretty soon your blinkers wont work. and in my case, the tail lights both burnt out and the flasher got fried.

I have a blinker switch for a 91 type, brown back connector. I got a spare to keep on hand cause they go out so much. it will replace any switch with a brown plastic back.
lemme know if you need it.

 

I had a problem with the headlights flickering and flashing at random. I had to replace the headlight switch. Parts counter guy at the Ford dealership here also recommended replacing the portion of the harness that the H/L switch plugs in to. When the switch croaks it overheats and melts down the harness socket.

The instrument panel has to be opened up to do the repair, of course. Replacing the harness will require soldering - wire nuts or crimp connectors in a high amperage application like this are asking for trouble down the road. I would also recommend buying some heat-shrink tubing to insulate the soldered connections because it's easier to use in tight quarters and it does a better job.

The advantage of replacing the harness is that you can extend the wiring about 8", which makes it a lot easier to reassemble the dash than it was to take apart.

The switch & harness, with taxes and all came to less than $100 Canadian ( about $60 US. I made this repair 2-1/2 years ago and have had not further trouble. From other posts on the forum replacing the switch only will be good for six months to a year.

Good luck with your repairs.

Cheers,
Eric

 

This is a good reason to install relays to power your lights. It takes the load off of the switches and stock wiring harnesses.

 

My 93 F150 is having trouble with the headlights flickering again. I had the dealer replace the switch and harness about two years ago. I want a repair that will last permanently. Is there an aftermarket alternative? What about these relays mentioned below? Where do I get them and are they difficult/exspensive to install?

Frustrated!

EW

 

It's pretty simple to install relays to switch your lights. You can get 30 amp relayds from Radio Shack; they have these 1 cubic inch black box relays designed just for this purpose. You can also get fuses from them. I have seen relay/fuse combinations before, so you can look for those at your local auto parts store.

The easiest way is to intercept the wires that go to the headlights. You should install a separate relay for each of the high and low beams. Take the low beam for example. Find the wire that feeds the low beam filament and cut it. Connect the end coming from the light switch (toward the cabin) to one of the relay coil connections. The other end of this coil connection should be grounded. When you turn on the light switch, it will activate the coil, and close the relay contacts. Connect a thick wire (with fuse) from the battery positive terminal to one of the relay contacts. Connect a thick wire from the other relay contact to the other end of the wire that you cut, feeding the low beam filament. There are standardized connectors that plug into the spades on the relay, with each spade numbered, and standardized conventions for connecting which wire to which spade. But I don't think I've ever followed them.

Find a secure and somewhat protected place to install the relay. Repeat for the high beams.

 

I had the problem with the headlights also. Then one night both low beam lights blew, Repalced the turn\high beam switch and no more problem.

 

All,

I've had the problem with my A*s several times, exacerbated by my always driving with my headlights on. The problem was always the dash-mounted headlamp/interior light switch. Replacing the switch solved the problem, ususally for good because I believe the replacements were of higher quality than the originals.

I sure can't argue with the recommendation of installing relays! THAT would ensure closure to the problem...

DadVan