I want to start off by thanking everyone who posts here and for the helpful information you give.

I have read the posts dealing with the blinking headlight problem so this weekend I replaced the Dimmer/turn signal/wiper arm assembly switch. Picked-up a used one from our local junk car yard for $46. I also had to replace both headlights because the dims were blown. I opted to try the expensive best halogen bulbs at $25 each. I didn't notice a big difference but I wonder if the ones I took out were not bright ones already. The code on the bulb was an SA (I think). While I had the lens covers off I scrubbed them down with some rubbing compound to get rid of some dings and the yellowing. I was surprised at how well it worked. I still need to do some rubbing with some fine sandpaper to get rid of some of the dings but the compound did get rid of the yellow tint. So here I sit...down $100...and the headlights still blink.

Let me back-up and give some history...I had to replace the wiring connector on the back of the headlight switch a few months ago because it over-heated and burnt out the connector. I didn't replace the switch...next thing on my list...I did have one in my hand at the junk yard Saturday but I couldn't remember if I had replaced it yet or not...(I read a past post here this morning and realized I didn't so I am off to the junk yard again). I also had to replace the electrical switch on the drivers side for the front windows. It too had over-heated and burnt the connector and the switch. And now I have replaced the dimmer switch.

Could my current problem (headlights flickering) be the headlight switch and NOT the dimmer switch? Could I have put in a bad dimmer switch from the junk yard? Or is it both? Any ideas??????

Reid in Spokane WA

 

Do you have a Canadian Aerostar?

 

Not to my knowledge. I do live in WA state so there is a possibility. Why? How do I check?

Reid in Spokane, WA

 

sounds like you have the newer aerostar. i have the blinking headlamp problem as well. but since i was going to run a relay driven headlamp harness upgrade... i didn't bother replacing the headlamp switch. swapped in the new harness and problem solved. not only that, my headlamps are now much brighter than it use to be. fortunate for me, i have the seal beamed and glass version. no oxidation to deal with at all.

the wiring harness is pretty simple to built yourself. its basically taking your existing headlamp power to trigger the relay. its the relay that supplies switched power to the headlamp. this way, the length of wire between the battery and the headlamp can be shorten significantly. 1 relay for lo beam, 1 relay for hi beam. and since the OE headlamp switch is only supply much smaller current just to trigger the relay, it does not overheat. and no blinking headlamp problem... i guess you can say permanent fix!

here's a pic of the wiring diagram.

even tho this shows the hid system. just replace the ballast with your bulb instead. i've used this to develop my wiring, just duplicate it for the high beam portion of the circuit.

 

I mentioned the Canadian model because of the day time running light module. If you have the US one, no matter.

 

In our Aerostar, I had problems witht the headlights dimming and/or going out completely. Ended up replacing the dimmer/turn signal assembly with a new one for less that what you paid at the junkyard. Fixed the dimming problem, but the headlights would still occasionally drop out. Turned out to be the headlight switch. The plastic connecter was all melted from arcing and stuff. Instead or repalcing the connector, I bought a box of female spade connectors and fixed it that way. Works very well, and has not given us any trouble since then.

 

Hi, I´m also still having problems with flickering headlights on my 1993, V6, 4.0 Aerostar. Today I got the switch out, and found the connector all burnet and molten. It is my intention to change both the switch and the connector, but I haven´t been able to find a replacement in my country´s (Uruguay) dealer. I entered the Motorcraft web page with the parts number on my switch, but could not find any. The one Y found has a different parts no. and I am not sure if it will fit.

Any suggestions as to where I can find a replacement switch and connector online?

 

Sure. I purchased my switch at Autozone, and you can order their products online. I don't know how much it would cost to ship it to you though. Their site is www.autozone.com. Another one, which might be a better bet, is www.rockauto.com. They have really low prices, and might be your best bet. As for the connector, if you buy a box of female spade connectors, you can cut the original wires, and then crimp the connectors onto the spade connectors. Make sure the connector you get fits tightly onto the blades on the new switch. When you begin make sure you cut the wires one at a time, as close to the old connector as possible. Then crimp on a connector and immediatly place it onto the new switch before moving on. That way, you prevent any mix ups. This method will hold up better than Ford's original connector.

 

Kind of semi-off-the-topic but I just replaced my bulbs with mega bucks PIAA bulbs and they sucked..... until I re-aimed them. I didn't think just changing bulbs would cause the beam focus to change, believe me it does! I had to make wholesale changes to my headlight adjustment to gain the $100.00 worth for the new bulbs.
PS MY headlights flicker on and off all the time when they are not turned on. Yes, I have a Canadian van with daytime running lights.
007BRONCO

 

Barry FS,
My headlights are on whenever the van is cranked. Does this make it a Canadian model? What effect does this have on my problem? Except for the fact the low beams keep blowing because they are on all the time.

Aerovan,
Thanks for the wiring diagram. I think I might just have to rewire my vans headlights. I have the same kind of relay wiring set-up for my extra lights. I have halogen driving lights mounted on the top of my bumper and they can only come on when my high beams are on. I have fog lights mounted under the bumper and they can only come on with the low beams. I tied into the lights wiring just before the left head light. I fed the high/low power back to two relay switches. These control the power coming from the switches mounted under the dash board. I cut them all out when I started having the flashing headlight problem because I thought they might be causing problems.