Headlights stopped working?
 

Hey guys,

Tonight on the way home from dinner, the headlights on my '89 GXL stopped working. When using the headlight switch, the marker lights work correctly, but the headlight motors do not raise and the headlight bulbs do not illuminate.

The motors raise and lower fine when using the retractor switch, but the bulbs do not illuminate (when headlight + retractor switches are both on).

The 30a headlight fuse in the engine bay looks ok (if it were bad, I'd expect the marker lights not to work either?).

Hoping someone has run in to something similar and might have an idea. Perhaps the switch itself? Anything else to check before I dig in to the instrument/switch cluster?

Many thanks in advance,
mint

Try a flash-to-pass (lights off, flick high beam to on...light should be visible through the lens)-this at least tells you the bulbs are good and, coupled with the knowledge that the retractor motors work, kinda narrows the search to the main light switch or possibly, the harness behind it.

Check the Red wire (there are 2 to choose from) at the headlight relay as they are powered constantly by the head fuse thus no key and leave the headlight switch in the off position and see if the Red wire has 12 volts or not.

Marker lights are powered by the illumination fuse and not the head fuse.

Thanks guys.

Flash-to-pass works correctly.

And assuming I am testing the right thing, the red wires on the relay are good too(4-connector relay with 2 red wires on the upper row and a white/blue and red/green on the lower row, see attached image). Both red wires show 12 volts with the headlight switch all the way off and without the key in the ignition.

Any other things I might check before throwing money at a new switch, and/or tips on a good place to buy a used or reconditioned switch?

Thanks again, definitely appreciate the advice.
mint

Ground the White/Blue wire to see if the lights turn on. if they do then the relay is good but the switch is at fault for its job is to place a ground on the White/Blue which activates the relay that turns on the lights.

The headlight switch also places a ground on the Red/White wire of the headlight switch harness which causes the lights to pop up. Your harness might be damaged and a visual check will tell you so.

Thanks Satch. Grounding the white/blue wire does cause the bulbs to illuminate correctly. I did a quick visual inspection of the harness and don't see anything obvious (no scorch marks on the connectors or cuts/melting of wire casing. Also did not smell anything burnt on it).

I guess this points to the switch. Looking at new switches (mazdatrix, Atkins), they list separate parts for S4 vs S5. But eBay and 13betc seem to say that the same switch fits all 86-91. Do you have any guidance on this?

Thank you again,
mint

I've messed with different series switches.
S5 switch in an s4 had a hum and scared the shit out of me to keep on.Knowing that any discrepancies can burn the harness out I just found the appropriate series switch.

Seriously if I was in your shoes ( I hope you wear a size 8..because I need new ones!..lol!) I would just go with the same series switch.

Hey fellas,

Wanted to say thanks for the troubleshooting guidance on this. Switch was indeed the problem. New switch arrived yesterday and the headlights and motors are working great again.

Happy for tilt wheel for sure; it gave me just enough room to wiggle the instrument cluster surround off without having to remove the wheel or do something to the wheel surround.

Thanks again, very much appreciated. If you call the Portland area home or happen to be in town sometime, pm me, dinner and beer are on me.

mint

Good to hear.