Odd Headlight Problem on my 91 XLT V6

[imthedude101]

Issue:
The headlamp work most of the time. Sometimes, they wink out. It doesn't matter if they are are high or low beams, they just cut out. I can turn on the passing lights for the few moments the mains are out, but this is dangerous. Also, sometime it will only happen once, then everything is fine for the next hour or so. Sometimes it happens repeatedly like every minute or a couple of minutes, then everything will go back to normal. This has occurred both within a few minutes of starting the engine to after having driven for an hour or more.

I have attempted to associate this with driving conditions (hot, cold, wet, dry, bumpy, smooth, etc) and there is nothing external that appears to be the cause. I thought maybe a loose connection, but that would be evident if this occurred under bumpy conditions. I have double checked all of the dry checks in the engine compartment.

My mechanic thinks it would be the Turn Signal switch assy, but I am very skeptical of this analysis.

Any thoughts or ideas out there?

Regards,

Eric

[mehedgec]

It happened to me several times a few years back, and my buddies Explorer. I think it is a known issue so someone will know for sure here.

Mine hasn't done it since then though, and I feel like it may have something to do with the battery cables, because soon after it happened to mine, one just broke off right at the terminal end. I replaced the terminal ends and have never had it happen since then.

Again, I have no idea if the 2 are related. Headlight switch has also been replaced because I burnt the rheostat after installing my headunit.

[FIND]

The turn signal switch, or multifunction switch as it is usually called, can very well be your problem. Note sometime how your lights turn off between switching between high and low. This is because the switch trips a relay that turns off your lows and turns on your highs. A bad switch can absolutely cause you to lose low beams. Of course, the problem could also be elsewhere, the only real way to know is to begin testing components or find signs of a worn out component.

[imthedude101]

Thanks for the suggestions all. Anyone able to tell me how difficult to replace or how to do it?

[Maniak]

It is actually pretty easy to change the multi function switch. Basically,you pull the cover off that is around the steering column. You then remove IIRC, 3 screws and 2 connectors and viola.. Its out.

Reinstalling the the reverse.

~Mark

[imthedude101]

so the 3 hrs the mechanic is trying to charge me is just a bit too much.

[Maniak]

It just so happens, we don't run with the cover over our steering column. Here are a few pics of how the multi function switch is held on (its only 2 screws) and the 2 connectors that come off the switch.


1992 Explorer multi function switch 001 by maniak_az, on Flickr


1992 Explorer multi function switch 002 by maniak_az, on Flickr


1992 Explorer multi function switch 005 by maniak_az, on Flickr

~Mark

[imthedude101]

Thank you very much! I think you just saved me about $200!

[Anime]

The headlights going out is usually the headlight switch itself. You can tell for sure if they go back on when you pull the switch out a little more and it will click and the headlights will stay on, or if it's really gone then even that won't turn the lights back on, and you need to push the switch back in and pull it out and then they work again.

The switch is rather inexpensive, especially aftermarket, and pretty simple to swap out, just yank off the front of the dash to get to the switch, unscrew the bolts, disconnect the harness from it, reattach the new switch, bolt it back up and push the dash trim back on.

Also worth noting, this can turn into a safety issue as the switches can cause a fire when they really go bad, besides your headlights going out on you in the dark being a problem.

[FIND]

Since you just saved so much money, replace both

[91explorer4x4eb]

I had the same thing happen in my 91. I replaced the Headlight Switch and it seems to have fixed the problem. It was a pretty easy fix, which I was thankful for since it was snowing when I had to do it.

[rsw2008]

this happened to me also on my 91ex. seams it was the red wire that goes in the switch. i just put a spade(female) terminal onthe red wire. yes i know which red wire is it ? just wiggle the red wires tlll you find the right one just like i had to do.

[hondakillah]

I just had to do this in my 93 ranger (same headlight switch as you). But I had just replaced my headlight switch, and this problem reoccurred. The harness that holds the wires in place on top of the switch wasn't holding my wires in place, so the power wire to the headlights slipped off it's prong.

My simple, ghetto-fix was dielectric grease on the spade and above it, and then put some hot glue over the top of it to hold the wire in place.

My original problems were the occasional flickering of the headlamps. The lights would go out when I rotated the dimmer switch (thus the replacement of the entire switch). A month later when I started my car and switched on my headlights, they turned on, then immediately off. I threw a tantrum and stayed the night where I was. Next day, I tore into the dash to see the originally mentioned problem.