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7.3L IDI Diesels (Not Power Strokes) Technical discussion of topics related to vehicles powered by the 7.3 Liter In-Direct Injection Navistar engines.

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Old 08-15-2009, 11:56 PM   #1 (permalink)
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bad headlight switch symptoms

A couple of months ago, my dash lights started to flicker and then went out completely. Recently, I lost my rear running lights (tail lights). Checked all fuses and obvious wiring...nothing unusual.

Yesterday, I bought a replacement headlight switch $25 (Made in India). Pulled the old switch and found a melted wire harness (also hot to the touch). Back to the parts store and bought the headlight wiring harness $18 (Made in India).

Spliced in the new wiring harness and installed new switch...ALL lights are working again.

--Hugh

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Old 08-16-2009, 10:35 AM   #2 (permalink)
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Common problem....... nice recovery.
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Old 08-16-2009, 11:07 PM   #3 (permalink)
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Hey,
good job, though may I suggest this:

I had the same symptoms, but my truck would also attempt to start itself without the key in the ignition.

I discovered the cooked harness at the switch, but it wasn't shorted, especially to the s-terminal for the starter. I tugged/jiggled on the wires to the switch for a spell (from the switch side) and it blew the fuse.

I pulled the dash and discovered the wire feeding the running lights had melted through the insulation and welded itself to the exciter wire.

I would suggest checking deeper into that, just incase your wiring was melted like mine, it may crank itself stuipd one day, or worse, destroy the flywheel if that is the case. Or just burn.

Good luck.


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Originally Posted by waterdude007 View Post
A couple of months ago, my dash lights started to flicker and then went out completely. Recently, I lost my rear running lights (tail lights). Checked all fuses and obvious wiring...nothing unusual.

Yesterday, I bought a replacement headlight switch $25 (Made in India). Pulled the old switch and found a melted wire harness (also hot to the touch). Back to the parts store and bought the headlight wiring harness $18 (Made in India).

Spliced in the new wiring harness and installed new switch...ALL lights are working again.

--Hugh

TDS rocks!
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1993 f250 ext cab. 4x4 7.3 N/A w/k&n filter and new injectors, and smokes like mad.
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Old 08-16-2009, 11:36 PM   #4 (permalink)
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On the subject of burning wires, shortly after buying my truck, my turn signals went out with a big puff of smoke. I found out that the previous owner installed a LARGER fuse in the turn signal slot, probably he was tried of the fuse blowing all the time.

Replaced my battery cables a couple of years ago along with a new voltage regulator, so voltage is full tilt now.

Always something...

--Hugh
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