1st Generation Specific (1979-1985) 1979-1985 Discussion including performance modifications and technical support sections

headlights suddenly stopped working

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Old 11-14-20, 06:58 PM
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headlights suddenly stopped working

Went out for a little drive tonight and flicked on my headlights. The headlights popped up and turned on as per usual however a few seconds later the headlights both stopped working at the same time. The popups stayed up, gauge cluster lights were on and blue headlight light in the gauge cluster stayed on but no headlights. Cant seem to find any loose connections and seems very unlikely that both bulbs would quit at the same time without warning. Has anyone had this issue before?
Old 11-15-20, 10:09 AM
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Fuses. Combo switch. Rats ate through the wiring harness. Pick your poison.



Last edited by impulsive-rx7; 11-15-20 at 10:22 AM.
Old 11-15-20, 10:26 AM
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Fuse likely, tho as a safety feature, its failure may indicate an underlying prob, so beware.
Fuse box has a fuse, but I think lights also tied into the three MAIN fuses, on the driver strut tower.
These are BIG, with a loop of wire on each. Check these as well. And wise to buy a spare or 2 for future needs as these are rather unique.

Stu A
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Old 11-15-20, 07:36 PM
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Does each individual pop up have a fuse or is it shared? Iv been wondering since my right side pop up stopped working and i haven't bothered trying to fix it since ist most likely the motor that gave out and i don't wanna spend money on it just yet,
Old 11-15-20, 09:24 PM
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Originally Posted by 7aull
Fuse likely, tho as a safety feature, its failure may indicate an underlying prob, so beware.
Fuse box has a fuse, but I think lights also tied into the three MAIN fuses, on the driver strut tower.
These are BIG, with a loop of wire on each. Check these as well. And wise to buy a spare or 2 for future needs as these are rather unique.
As Stu is trying to say, the fusable links on the drivers inner fender. There are three wires that are actually fuses. One of them controls power to the head lamps. Turn the lights on and wiggle the ends of the wires to see if the lights come back on. You may want to remove the wire(s) and clean the terminal ends both on the wire(s) and contact block.

Frogmans problem is most likely the small relay clamped to the side of the RH headlight motor. (under the rubber cover) Tap on it a couple times. If that doesn't work remove it and take off the metal cover. Inside, it has contacts like a set of points. Gently file the face of the contacts with a fingernail file and try again.
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Old 11-15-20, 10:14 PM
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T
The links should look like this ( not my image but i can take one if you need help)
Old 11-16-20, 09:13 AM
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Final (?) thought is to check the condition of the headlights actuator arms. There are 2 on each assy, with nylon pivot points that pop on to a ball socket. These should be cleaned & lubed (yearly). Often with age the nylon inserts are failing/broken. Arms need to be replaced as complete unit (4 total) and are avai new from Mazda (about $120+ on various ebay listings for a set) -OR: a forum member here has re-created just the nylon inserts which you can refit into the existing arms: $35-ish.

Stu A
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Old 11-16-20, 12:29 PM
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This happened to me many years ago and it turned out to be the multi-function switch. I replaced it with a used one and it has worked since. Maybe hitting it with contact cleaner will get it working.
Old 11-17-20, 04:41 PM
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Also, the "blue indicator" on the idiot lights is for when your BRIGHTS are activated. The combo switch is notoriously bad for not being able to carry the amperage through its small switches and wiring for the high amperage draw which your headlights require. You might try pulling back on your headlight stalk and see if the standard bulbs come back on. The core issue is that with age and internal corrosion of the wiring components, the current draw becomes too high for the switch to carry, which results in carbon arcs across your switch contacts.

The only true long-term fix is to retrofit a relay-based lighting harness which moves the high amperage draw circuits to stand-alone relays, leaving your column switches to just carry the switching loads, which are greatly reduced (milliamps vs. amps). Black Dragon used to sell these harnesses as a plug and play option, and they work wonderfully.

As the guys have said, have a look at your fuses and Fusible links, but first, turn off your brights, as that will confound the troubleshooting steps.
Old 11-17-20, 05:35 PM
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Hey LongDuck,
Since Black Dragon is out of business, are there any of these harnesses still floating around?
Old 11-17-20, 05:37 PM
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As of last week, I don't have headlights, clearance lights, or dash lights. They're failures are all pointing to the combo switch. The only time I get the headlights to come on is if I pull back on the turn signal stalk. An upgrade harness with relays would be great.
Old 11-17-20, 09:21 PM
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Originally Posted by mjm4jc
Hey LongDuck,
Since Black Dragon is out of business, are there any of these harnesses still floating around?
I got one on Amazon. No complaints for the cost.
Old 11-17-20, 11:34 PM
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Originally Posted by LongDuck
The only true long-term fix is to retrofit a relay-based lighting harness which moves the high amperage draw circuits to stand-alone relays, leaving your column switches to just carry the switching loads, which are greatly reduced (milliamps vs. amps). Black Dragon used to sell these harnesses as a plug and play option, and they work wonderfully.
If the switch electrics are not compromised, may I suggest an alternative, which is to swap in LED headlamp bulbs. Very low draw (less than stock), spectacular improvement in photon output, plug-and-play install. (Requires H4-compatible lamp housing. I used Hellas...)

Amazon Amazon

Been using these in my SA for a year now.

Stu A
80GS
AZ
Old 11-18-20, 08:25 AM
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Originally Posted by 7aull
If the switch electrics are not compromised, may I suggest an alternative, which is to swap in LED headlamp bulbs. Very low draw (less than stock), spectacular improvement in photon output, plug-and-play install. (Requires H4-compatible lamp housing. I used Hellas...)

https://www.amazon.com/BEAMTECH-Head...6-05ac39e80cc0

Been using these in my SA for a year now.

Stu A
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That is an excellent suggestion indeed. I will take the combo switch out and look at it. As long as nothing is melted, hopefully I can just clean it up and use it.

I don't know much about the LED headlights. I love the look of a bright halogen, especially the Sylvania Silverstars. But I guess I'm open to LED's. Do you really think that they give greater visibility and light down the road?
Old 11-18-20, 08:34 AM
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7aull,
As far as the lamps are concerned, do you mean something like this?

https://www.amazon.com/IPCW-CWC-7006-Plain-Conversion-Headlight/dp/B001OMEPEU/ref=mp_s_a_1_4?dchild=1&keywords=H4+7"+headlight&q id=1605709890&sr=8-4
Old 11-18-20, 09:37 AM
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Here's the harness I used. Note that this would be fine for standard hi/lo wattages and LED replacement, but pushing it for "high power" halogens at like 65W and more.

As suggested above, make sure your switch contacts are good at the stalk before putting something like this in.

Amazon Amazon
Old 11-18-20, 09:42 AM
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Originally Posted by mjm4jc
7aull,
As far as the lamps are concerned, do you mean something like this?

https://www.amazon.com/IPCW-CWC-7006-Plain-Conversion-Headlight/dp/B001OMEPEU/ref=mp_s_a_1_4?dchild=1&keywords=H4+7"+headlight&q id=1605709890&sr=8-4
Yes, these would work if they accept (presume they do) standard 'H4' socket. I can't speak to the optical quality of the lense of course. Its the glass that shapes, focuses the light, which the Hellas and Cibies do so well...

Stu A
80GS
AZ

Last edited by 7aull; 11-21-20 at 10:17 AM.
Old 11-18-20, 09:42 AM
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concerning the harness, will one relay not work? it shows 2 relays. way back when i had my 808/rx3 i only used one relay on the high beams cause i was running 50w aviation/marine lights. never had an issue running only one.
Old 11-18-20, 09:46 AM
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Originally Posted by mjm4jc
I don't know much about the LED headlights. I love the look of a bright halogen, especially the Sylvania Silverstars. But I guess I'm open to LED's. Do you really think that they give greater visibility and light down the road?
The point of my suggestion is to reduce the load on your electrics. Using halogens will do the opposite, which is why Longduck was recommending the relay system. FWIW I had halogens in my SA before I switched to the LEDs. The diff was breathtaking. And so simple to install. Think you will be pleased...

Stu A
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AZ
Old 11-18-20, 09:54 AM
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Stu,

Are the Beamtech LEDs you suggest the exact ones you are using, and are they blue or white in practical use? Thanks!
Old 11-18-20, 10:34 AM
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Yep. White.


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Old 11-18-20, 10:52 AM
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Originally Posted by Toruki
Here's the harness I used. Note that this would be fine for standard hi/lo wattages and LED replacement, but pushing it for "high power" halogens at like 65W and more.

As suggested above, make sure your switch contacts are good at the stalk before putting something like this in.

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
I have an original Black Dragon harness and this PutCo harness. They are virtually the same harness.
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Old 11-18-20, 06:30 PM
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Originally Posted by 7aull
Yes, these would work if they accept (presume they do) standard 'H4' socket. I can't speak to the optical quality of the lense of course. Its the glass that shapes, focuses the light, which the Hellas and Cities do so well...

Stu A
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Ok, so if I were wanting to go with a cheaper LED bulb that will fit the standard 7" housing with the H4 socket like you said, are there any other brands that you would recommend? $40 per bulb is a bit steep for me, considering I have to buy the headlight assemblies too. There are the ones that don't have a pigtail, but just plug right into the stock harness.
Old 11-18-20, 06:49 PM
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My bad, I just noticed that the price for the BeamTechs is for a pair. I guess that makes it a lot more reasonable.
Old 11-19-20, 02:47 PM
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Don't go cheap on leds! You'll regret it down the road.


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