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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 01-04-2006, 09:22 PM   #1 (permalink)
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Burnt headlight switch

OK I know that its comon for the headlight switches to burn out, My question is what can I do to avoid it again? My new switch has lasted 1 1/2 years and the running light wire is starting to burn again. I only have 4 lights on the rear bumper that are not OEM and they have #194 bulbs. I dont know why this would be too much curent for the switch. I am planning to do the headlight relay conversion, but is there something I can do for the running lights?
I could just replace all the light bulbs with LED's [img]/ubbthreads/images/graemlins/biggrin.gif[/img]
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Old 01-04-2006, 11:03 PM   #2 (permalink)
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Re: Burnt headlight switch

I did the same trick to the running lights on my box truck. The headlight switch now triggers a relay for the running lights. The relay will handle 30 amps sustained and 40 amps initial rush. That is a lot of chicken lights!!!! [img]/ubbthreads/images/graemlins/biggrin.gif[/img] Subnote: if the wire is giving troubles because of trailer lights etc. simply split the load to 2 relays. Semi's do this on the 7 wire trailer cord. One side runs the upper I.C.C. lights, and the other runs the lower set. Same holds true of modern trucks with lighting systems that cannot take an additional load for a trailer. The fancy solid state light box (Hoppy etc.) gets a minute trigger signal for operation and then supplies trailer requirements from a battery feed.

firedane
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Old 01-04-2006, 11:16 PM   #3 (permalink)
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Re: Burnt headlight switch

I've thought about a relay setup, but I cant think of a good way to wire it. Did you wire in at the switch or somewhere else? Anyone have a diagram on this?
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Old 01-04-2006, 11:30 PM   #4 (permalink)
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Re: Burnt headlight switch

Here is a link to the diagram you need. GO HERE . OkieGringo
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<font color="red">Link to GP Controller Diagram</font> <font color="blue">Link to "Electric Fuel Pump Wiring Diagram"</font>
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Old 01-05-2006, 10:20 AM   #5 (permalink)
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Re: Burnt headlight switch

Very cool! "Hey! Go easy on those beers now!" [img]/ubbthreads/images/graemlins/wink.gif[/img]

Okay, is there a similar site/diagram that shows the running lights?

Jim
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Old 01-05-2006, 11:13 AM   #6 (permalink)
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Re: Burnt headlight switch

[ QUOTE ]
Very cool! "Hey! Go easy on those beers now!" [img]/ubbthreads/images/graemlins/wink.gif[/img]

Okay, is there a similar site/diagram that shows the running lights?

Jim

[/ QUOTE ]

Just use the same wiring setup for another relay. Find the wire out of headlight switch that normally turns on the running lights and cut it, butt the wire to energize the relay.OG
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<font color="red">Link to GP Controller Diagram</font> <font color="blue">Link to "Electric Fuel Pump Wiring Diagram"</font>
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Old 01-05-2006, 06:02 PM   #7 (permalink)
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Re: Burnt headlight switch

Their are 2 mods that you can do, one is for the headlites and the other for the running lites. Easiest for the headlites is to buy the "kit" from summit racing equip. It is just a plug, and is about the same $ as buying all the parts. The running lites use a 12volt spdt 30a relay. Tap into the power wire of the switch - connect to #30 on relay. Cut the running lite wire, switch side to #86 on relay the other side of the wire goes to #87. Ground #85. (you can find the relay and connectors at you auto parts store ask for a fog lite relay switch kit about $8.00) hope this helps
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Old 01-05-2006, 06:22 PM   #8 (permalink)
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Re: Burnt headlight switch

Does anyone have the part number for this switch? Fordpartsnetwork.com does not seem to have any in stock... or they're REALLY selling them for $0.00....

Thank you,

Mike
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Old 01-05-2006, 10:15 PM   #9 (permalink)
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Re: Burnt headlight switch

[ QUOTE ]
Does anyone have the part number for this switch? Fordpartsnetwork.com does not seem to have any in stock... or they're REALLY selling them for $0.00....

Thank you,

Mike

[/ QUOTE ]

Mikey, Mikey, Mikey, get your tail back to work on that "thesis". They'll have the parts "back in stock" by the time you get your "Degree" in 3 months [img]/ubbthreads/images/graemlins/rolleyes.gif[/img]. [img]/ubbthreads/images/graemlins/shrug.gif[/img]OkieGringo
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<font color="red">Link to GP Controller Diagram</font> <font color="blue">Link to "Electric Fuel Pump Wiring Diagram"</font>
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