Euro HDJ80 Dimmer relay

[loucaojr]

Hi,

So last night while cruising my main and high beams went off... Checked the dimmer relay and there was my problem again... A burned relay as you can check in the pic, this was 2.5 years old.
Placed a spare relay that was carrying, also busted but at least I had main beams.

I know it's a fairly common issue.. But what can I do to make it better and last longer? This relay had a pretty short life... And I'm just running the stock H4 + H1.

Please comment.

Cheers

 

[alexandruast]

Mine lasted ~ 30 days. Pry opened it and found out that the contacts were poorly aligned. Sanded the oxidation down and properly aligned the two contacts so they are flushed when the relay engages. Do not align by bending the steel spring plate that actuates, but the contact that is at rest. You might need a very thin needle nose pliers for this.

 

[Squash]

Have you solved this?
My 1995 hdj80 lost high beams and dash indicator.
No power to high beam fuses, but can light the high beams if I jumper a fuse.

 

[Gerry McGerry]

Have you solved this?
My 1995 hdj80 lost high beams and dash indicator.
No power to high beam fuses, but can light the high beams if I jumper a fuse.

Either the dimmer relay or the combination switch.

Use a jumper at the dimmer relay, then flash your high beams. Should rule out which of the two has bunged up.

 

[Squash]

Works when jumpered.
Leaning towards a wire because this happened at night after a bigger bump of many bumps on a 80km logging road used as a shortcut between two highways during my latest 1000km ski/fishing trip.
Luckily I have a roof rack mounted light bar on a separate circuit.
I had the stalk out and cleaned yesterday, it looked and felt proper.

 

[Gerry McGerry]

Works when jumpered.

but can light the high beams if I jumper a fuse.

Just to clarify, are you saying you've jumped the fuse or the relay?

Do you have an EWD of the euro headlight circuits? I can upload a few pages if you need, not sure if there are euro spec EWD's in the resources.

 

[Squash]

Jumpered the DIM relay and the high fuse/s
Either way the hi beams and blue Dash indicator light up.
I believe the manuals are pretty close, so thanks in advance.
In the process of getting a whole stalk assembly and or part # 84140-12260 which also was used on Corollas from 1987 to 1995 and Celicas from 1987 to 1989.

 

[Gerry McGerry]

Attached a page anyway, may help someone in future.

Have you tried pulling the relay and testing it on a bench?

Had to replace the switch on a mates 80 not long ago for the same issue, but Aussie spec 80's don't have the extra dimmer relay.