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Headlights on, Headlights off, on, off, on, off .......

HeadWizard

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I seem to be having an intermittent issue with my lights. Found this while driving home from a Lions Club meeting a few weeks ago. Was right next to the Courthouse/Jail in Fairfax (yes, city police in view) when my lights just go out and yes, it's dark out.

After uttering the appropriate phrases loudly while trying to see where to park on the dark side street, I am helped by the helpful officers spotlight. :shock:

I wiggled the switch, the wires under the dash - nothing. A couple minutes later, the lights just come back on by themselves :? The officer escorts me to the city limits.

10 minutes later on a narrow, lightless, wooded back road at 35 mph, the lights goe completely dark again. I can't see much past the hood and certainly the lusterless 3 color camo makes it easy for other drivers to see me. I find a driveway to pull into and futz with the wiring and switches for some reason. Nothing.

I figure the worst thing that'll happen is that I'll mash something in the 3 miles left to home so I take off lightless. A mile or so later the lights magically come back on and stay on until home.

Next day I decide to get adventurous and disassemble the light switch (heck, it has screws on it so it must be meant to be taken apart). I was lucky and only lost 1 of the little springs that flew everywhere when it came apart! For those of you who haven't tried this repair, you should! The contacts were good and burnt looking. I went about burnishing up all the electrical contacts and applied dilectric grease. Had to take apart about 15 of my wifes pens to find one that had a close enough spring in it that I could rob to replace the one that went missing. Put the whole mess back together, installed the switch back in the truck and amazingly, the lights came on!

My feeling of accomplishment was dashed when about 5 minutes later the lights went dark again. I haven't driven it in the pm since....

SO does anyone have any suggestions as to what might be the cause of the intermittantly operating lights? Any and all help is greatly appreciated.
 

Recovry4x4

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Yeah, the circuit breaker on the firewall is breaking and resetting. Next you need to figure why. Try searching the site. Bjorn has covered this extensively. He even has relays on his headlights to avoid this overload.
 

gimpyrobb

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Not to question your rebuild ability, have you tried another 3 lever switch? I feel there is a short else where, but it is quick and painless to swap it out.
 

FreightTrain

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I would suggest not chancing that switch again.Buy a new one.Mine did the exact same thing after I got it.about 20 minutes the lights would all go out.5 minutes later they reset.Replaced the tripple switch and have not had a problem.
 

ken

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Does the black out lights run through the same circut breaker? I know the black out is a joke but mabye it's enought light in a emergency. Even though other drivers can't see you!
 

cranetruck

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Sounds like an overload condition. All lights are controlled by this switch and the built-in circuit breaker will trip if there is an overload (=short) in any of the circuits.
My headlights are now on a separate circuit breaker and controlled by a relay, which is the only thing the 3-lever switch "sees". Same for the flasher unit, which also easily fails if it is one of the new ones.
 

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HeadWizard

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That's why I love this site - lots of good answers. Didn't know there was a circuit breaker in the switch - didn't recognize it when it was disassembled.

I did try a search on this site and didn't come up with an answer - probably entered the wrong query? Many thanks to all who replied. Sometimes its more efficient to just ask the question and get the answer.

Sounds like I need to go "borrow" the switch off one of the other Deuces (which are stored elsewhere) and see what happens. Probably the best 1st option. Then I suppose I'll start tracing individual circuits.

Will advise what happens. Thanks again.
 

cranetruck

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jasonjc said:
The more a breaker tips the weaker in gets. So if one fails alot it needs to be replaced.
Unless you are talking thousands of cycles, it should not be a problem.
http://www.sensata.com/products/controls/tcb-chart.htm

Paragraph from circuit breaker patent shown below. Second image shows circuit breaker and the dimmer resistor.
 

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fireman9

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Chaplin CT
Mine does the same thing. I knew it was a circut breaker after I'd stopped and wiggled everything for the thrid time on the way home and the lights decided to come back on while I was scratchin my head in the dark. Luckly for me it only does it when I have the high beams on. Time for a relay! :-D
 

GoHot229

Member
As I'v said in other posts about electrical and cleaning the gunk and cruds on the terminals, White Vinigar .............it will etch it to like new and remove all the green oxides and you will have contact terminals that will make contact and flow electricity. Try it on some cruddy piece of loose wireing laying around to prove it to yourself, heat the vinigar in a sauce pan (or whatever) and soak the offending wire in it, let it set an hour or so, and wa...laaa....like new. I would say that the areas that are 'ARK' burned should be dressed up with a fine emery cloth to smooth. You may want to replace the whole wireing, then again you mabe cant afford it and want to fix it, this will work. You may want to remove the "Dialectic" grease with carb cleaner spray or the like first, the vinigar will not remove greases or petroleum substances of course.
 
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stumps

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An overload in the lighting circuit is unlikely, unless you have changed something, like running 12V headlamps on a 24V system :wink:

However, circuit breakers, particularly thermal circuit breakers, are notorious for lowering their tripping point when they get old... A 10A breaker behaves like it was a 5A breaker...

Replace the light switch/breaker and you should be fine.

-Chuck
 
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