Headlight rewire experts come in please? or need rewire??

I'd try a new switch I heard they were weak and did funky stuff often. My 95 had a poopy switch and it would turn the lights off alltogeather so I bought a new one.

There are myriad options. A simple one is to install relays on low and high beams, and fogs (3 relays). This unburdens the switchgear, which can extend the service life of the contacts.

Good luck.

SEE http://www.corral.net/tech/maintenance/foglights.html to fix the problem. The stock wiring isn't up to the job and is overheating. The headlight switch & turn/multifunction switch are affected by Ford's wiring problem. Sometimes it overheats so badly that the plastic shells of the wiring connectors start to melt.

Jaswir said:

what kind of relays where can i get some?

Click to expand...

Jrichker got you the goods.

If asking what I used directly, I simply used a Bosch SPDT (SPST would work fine as well) 30 amp relay x 3. One for lows, one for highs and one for fogs.

I tend to not be one to make a circuit more complicated than it was to begin (relays do occasionally fail, etc) but since peoples' lights sometimes go off on their own (a condition I consider extremely dangerous) I figured trying to improve the circuit (and adding more crap to it) was worthwhile. I will mention that the reason I added 3 relays was really to unburden the switchgear - it's over 100 bucks worth of switches that I wanted to avoid buying.

I chose to use resetting circuit breakers in series on the wire from the battery to the relay's common terminals. From when I used to rewire my bikes, I found that in wet conditions the breakers were effective for those occasional times when the circuit would get wet/whatever, and kick out. A fusible link might be even more application appropriate.

Bottom line is that simply following the link in Jricker's post should have you greatly improving things alone without introducing other sources of malfunction down the line. It is absolutely the place to start.

Good luck.