Headlight harness problem

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Posted by MAVman (75.162.100.87) on 19:44:10 10/27/08

Hey guys, long time no post---but I do check the board a couple of times per week. Not too much activity anymore--I miss the camaradie of the "good ol' days."

Let me just say up front that electricity and I don't get along! My neurons (or the lack thereof) are just not up to the task to diagnose anything beyond the basics. So with that official disclaimer, 1995 K1500, 350 with 221K miles (and still on the original fuel pump!!) Trying as always to improve the ride, I installed about 5 years ago the Kennedy Diesel headlight wiring harness. It's worked great until a couple of months ago. The low-beams work just fine but no high-beams--and when switching to high-beams, the lows now go out (the diode is in place for all 4 lights to come on when switched to high-beams.) I pulled the harness and inspected and found no visible issues. The grounds are great on both the left and right sides. I pulled the diode out and tested but still no high-beams. I've swapped the relays and the problem is unchanged. Tried a new relay but of course, no change. I tested power to the relay base and successfully "jumped" the power/high-beam circuit and they illuminated just fine. There seemed to be a short somewhere as I moved the harness around it would intermittently operate correctly. But I'm unable to replicate that. Bulbs have been checked and are fine. I did find corrosion on the connection of the Kennedy harness to the OEM wiring. But I cleaned with a file, used contact cleaner, and applied dielectric grease on the connection with of course, no change in the problem.

So I'm thinking the headlight switch itself or a short somewhere in the harness?? It appears to be a very high quality harness that I wouldn't expect to fail EVER. Any ideas? Any other things to check before taking it to the shop? Thanks!

Follow Ups:

Re: Headlight harness problem - Ben 22:46:11 10/27/08 (6)
- Re: Headlight harness problem - Maz 16:17:54 10/28/08 (5)
  - Re: Headlight harness problem - Ben 11:15:59 10/29/08 (4)
    - Re: Ben, you have a good memory - Maz 14:50:46 10/29/08 (3)
      - Re: What Happened to Us, Then???? - #1 Son 16:57:08 10/29/08 (2)
        
        Re: What Happened to Us, Then???? - Ben 10:13:07 10/30/08 (0)
        
        Re: What Happened to Us, Then???? - Ben 19:22:19 10/29/08 (0)

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Comments:	: Hey guys, long time no post---but I do check the board a couple of times per week. Not too much activity anymore--I miss the camaradie of the "good ol' days." : : Let me just say up front that electricity and I don't get along! My neurons (or the lack thereof) are just not up to the task to diagnose anything beyond the basics. So with that official disclaimer, 1995 K1500, 350 with 221K miles (and still on the original fuel pump!!) Trying as always to improve the ride, I installed about 5 years ago the Kennedy Diesel headlight wiring harness. It's worked great until a couple of months ago. The low-beams work just fine but no high-beams--and when switching to high-beams, the lows now go out (the diode is in place for all 4 lights to come on when switched to high-beams.) I pulled the harness and inspected and found no visible issues. The grounds are great on both the left and right sides. I pulled the diode out and tested but still no high-beams. I've swapped the relays and the problem is unchanged. Tried a new relay but of course, no change. I tested power to the relay base and successfully "jumped" the power/high-beam circuit and they illuminated just fine. There seemed to be a short somewhere as I moved the harness around it would intermittently operate correctly. But I'm unable to replicate that. Bulbs have been checked and are fine. I did find corrosion on the connection of the Kennedy harness to the OEM wiring. But I cleaned with a file, used contact cleaner, and applied dielectric grease on the connection with of course, no change in the problem. : : So I'm thinking the headlight switch itself or a short somewhere in the harness?? It appears to be a very high quality harness that I wouldn't expect to fail EVER. Any ideas? Any other things to check before taking it to the shop? Thanks!
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