I’ve had my 76 FJ40 for about 6 months, no electrical issues, and as I’m driving down the road last Saturday night my dash lights suddenly go out (after hitting a medium bump). After getting back home I realized it wasn’t just the dash lights but the whole circuit - parking lights, tail lights, etc. The 15 amp fuse at the top of my fuse box was blown, I replaced it and was immediately back in business. Figured the fuse had gone bad, no big deal.
Drove the 40 some the next day (headlights not on) and then checked the lights that night just to make sure everything was working - fuse blew as soon as I pulled the headlight knob out and lost the whole circuit again. I took all the bulbs out of every light on that circuit and the fuse blew again as soon as I pulled the knob out (even before headlights came on). Checked all wiring, harnesses, etc and no obvious exposed wire, shorts, etc. I took the headlight switch partially out, unplugged the harness, adjusted the dimmer a few times and then viola - everything worked again. My dimmer isn’t dimming for what it’s worth, only an on/off switch and I’ve haven’t gone to LED dash bulbs (yet!).
I checked the lights almost every night this week and everything worked fine, even after a short test drive. Took it out for a spin tonight and after about 10 minutes the same fuse blew. It seems like I’ve got an issue in my switch the best I can tell? Does this sound familiar to anyone? I’ve got the dash out and the headlight switch completely out, still don’t see any obvious shorts with the wiring except for two exposed wires coming from the middle of the dash that I’ve now covered up (don’t think they’re even on that circuit?). Is there anything I can do to take this switch apart and diagnose further (not an electrical guru)? It was a bit dirty around the connectors so got that cleaned up. Hate to just buy a new switch since I’m not positive that’s the problem and honestly not even sure if they’re available. Here are a few pics. Any and all help is appreciated, this is driving me crazy!
Drove the 40 some the next day (headlights not on) and then checked the lights that night just to make sure everything was working - fuse blew as soon as I pulled the headlight knob out and lost the whole circuit again. I took all the bulbs out of every light on that circuit and the fuse blew again as soon as I pulled the knob out (even before headlights came on). Checked all wiring, harnesses, etc and no obvious exposed wire, shorts, etc. I took the headlight switch partially out, unplugged the harness, adjusted the dimmer a few times and then viola - everything worked again. My dimmer isn’t dimming for what it’s worth, only an on/off switch and I’ve haven’t gone to LED dash bulbs (yet!).
I checked the lights almost every night this week and everything worked fine, even after a short test drive. Took it out for a spin tonight and after about 10 minutes the same fuse blew. It seems like I’ve got an issue in my switch the best I can tell? Does this sound familiar to anyone? I’ve got the dash out and the headlight switch completely out, still don’t see any obvious shorts with the wiring except for two exposed wires coming from the middle of the dash that I’ve now covered up (don’t think they’re even on that circuit?). Is there anything I can do to take this switch apart and diagnose further (not an electrical guru)? It was a bit dirty around the connectors so got that cleaned up. Hate to just buy a new switch since I’m not positive that’s the problem and honestly not even sure if they’re available. Here are a few pics. Any and all help is appreciated, this is driving me crazy!