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Gremlins-i need help from any electrical gurus out there

Discussion in '60-Series Wagons' started by Amamet, Jan 1, 2014.

  1. Output Shaft

    Output Shaft SILVER Star

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    One of the grounding junctions for the headlights is behind the gauge cluster. The entire gauge assembly needs to come out to gain access to it. On this model year, the ground junction is the small orange thingy with the green arrow pointing at it.
    headlight ground junction.jpg
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    This picture below shows the wire junction pulled out a bit to gain access to it. A burnt spot can be seen. This looks mighty suspicious. The blue wires are all connected to each other and the white/black wires are all (supposed to be) connected to each other, but the blue wires are kept separate from the ground wires by this special plug. It is not a single connection spot, but two.

    suspect1.jpg

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    Picture shown below shows the culprit. Obvious problem. This was the gremlin for all the weird headlight and dash indicator strangeness... one bad ground connection in this junction.

    All the white/black wires were removed from this connector and were cleaned up and all joined together and connected with a jumper to a known good ground to test if this was the problem.

    It was.


    burntPlug2.jpg



    Testing grounds test ground.jpg

    All the dash indicator lights then worked perfectly as did the headlights after this ground wire connection was fixed.

    >>>>

    Ultimately the question may be asked, "why did this happen?"

    25 years ago, high wattage H4 halogen headlamps were installed without upgrading the wiring harness with remote relays. The increased amp draw was beyond what the stock wiring and connectors were designed to carry.

    The increased current found a weak link in this grounding connector that only uses tiny sliding pins as junctions. The increased resistance at this poor-contact, pin to pin junction created excessive heat, which melted the plastic, creating carbon, coating the metal pin and female connector with insulating contaminates.

    Lesson learned from this particular problem:
    Always upgrade the lighting wiring harness with remote relays if upgrading to higher wattage headlamps... & it is a good idea to do so anyway if the stock sealed beams are retained.
     
    Last edited: Feb 7, 2015
  2. DoubleNickels

    DoubleNickels

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    Good Lord, thanks @Output Shaft , held my hand through my exact issue. Thanks again!
     
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  3. NeverGiveUpYota

    NeverGiveUpYota Dare me. SILVER Star

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    This thread needs to go into the stickys, @Cruiser Jimmy!!!! @Output Shaft, you out did yourself in making those connections understandable. I applaud you!
     
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  4. Spike Strip

    Spike Strip Adorable Deplorable SILVER Star

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    So, being lazy and not wanting to dig out a schematic, what are the larger blue wires for? I'm guessing the larger brown/black stripe wire is the Headlights?

    Could one just connect everything in a Bus Bar like this ?

    [​IMG]
     
  5. lovetoski

    lovetoski SILVER Star

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    Excellent thread - yes it should be a sticky!!
     
  6. Output Shaft

    Output Shaft SILVER Star

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    I don't know what the blue/brown wires connect to, but as I recall they are separated from the black wires inside that connector. All the black wires connected to each other & all the blue connected to each other.

    At first I was thinking the same thing of removing all the black wires & connecting them to a little buss bar connector, but after pulling them out of the connector, I then discovered how short they are and how little room there is to work in there. After chewing over the possibilities, I didn't think I could improve the situation by doing that, so I cleaned up all the pins with fine emory and reinstalled it back together.

    Ive heard of guys soldering the whole mess together. That's a lot of wires and which would require a big iron which would probably start melting the insulation.
     
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  7. Spike Strip

    Spike Strip Adorable Deplorable SILVER Star

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    @beno

    Is is possible that connector (or equivalent) is available?
     
  8. Cruiser Jimmy

    Cruiser Jimmy Moderator

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  9. Spike Strip

    Spike Strip Adorable Deplorable SILVER Star

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    Hmmmm..... Love that gooey deliciousness.

    :clap:
     
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  10. Toyoviatt

    Toyoviatt

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    Thank you! I was having similar problems-no headlights with buzzing relay, turn signal indicators both turning on when headlights triggered, fan super weak, turn signal indicators turning on when fan triggered. The wire connector behind the gauges as shown above was the culprit. Mine looked exactly like the one in the pic, last white ground wire burnt out. So glad this thread was easy to find.
     
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  11. 4Cruisers

    4Cruisers SILVER Star

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    Welcome to MUD, it's always good to see another member from the Land of Enchantment. Yes, a lot of helpful information here.