Wiring Success...and a New Problem
Thanks to the advice of several here, as well as a very excellent
treatise on headlight wiring on one of the FSJ websites, I was able to replace my headlight switchm get the lights all working and also restore my engine instruments at the same time. Now, however, a new (or maybe not) problem has arisen. When I turned on my headlights after completing the repairs, the Hi Beams were on. When I switch the floor switch to lo beams, the 20 amp fuse blew. I replaced the fuse and decided to test-drive the car with the lights on Hi Beam, in order to test the function of some other accessories I had hoped to have fixed. However, only a few moments after driving out of the shop, I noticed thin wisps of blue smoke emanating from behind the instrument panel. I immediately shut everything down and put the GW back in the shop. Now I am perplexed, because I cannot be 100 percent certain where the smoke was coming from. I pulled the instrument cluster, and looked at the new light switch. Frankly, it didn't look like that was the source of the smoke. There was no flashing or smudge on any of the wires, and when I pulled the switch apart, there was no sign of arcing or sootng of any contact or wire. Right now, I am going to trace out the dimmer switch wiring with a multi-tester to see if I can find a short there. Any further thoughts or advice will be greatly appreciated, and thanks again to all who weighed in and helped me get this far with it. Best regards, RB |
Re: Wiring Success...and a New Problem
Update--
Smoke was coming from the new light switch. I unhooked the connector after seeing wisps of smoke. The ceramic collar that holds the dome light "on/off" switch became extremely hot. I now suspect a short in the dome light circuit, but there could be a problem with any circuit on that switch. |
Re: Wiring Success...and a New Problem
Update--
Smoke was coming from the new light switch. I unhooked the connector after seeing wisps of smoke. The ceramic collar that holds the dome light "on/off" switch became extremely hot. I now suspect a short in the dome light circuit, but there could be a problem with any circuit on that switch. |
Re: Wiring Success...and a New Problem
Update--
Smoke was coming from the new light switch. I unhooked the connector after seeing wisps of smoke. The ceramic collar that holds the dome light "on/off" switch became extremely hot. I now suspect a short in the dome light circuit, but there could be a problem with any circuit on that switch. |
Re: Wiring Success...and a New Problem
Carefully check for a wiring error within your repairs. Also check wire
bundles for melted insulation and shorts that may be hidden. This secondary damage could have occurred during the fire as wires were burned and faulted. -- JimG 80' CJ-7 258 CID, HEI 4.56 Gears, Lock-Right F&R 35" BFG MT on 15x10 Centerlines D44 Rear, D30 Front. SOA Dana 300 w/4:1 & Currie twin sticks Warn X8000i w/ dual batteries 00' TJ Sport 4.0L, 5sp 4.56 Gears, TrueTrac rear 33" BFG AT on 15x8 Eagle Alloys D35 Rear, D30 Front. 3" Suspension Lift Warn X8000i > Update-- > > Smoke was coming from the new light switch. I unhooked the connector > after seeing wisps of smoke. The ceramic collar that holds the dome > light "on/off" switch became extremely hot. I now suspect a short in > the dome light circuit, but there could be a problem with any circuit > on that switch. > |
Re: Wiring Success...and a New Problem
Carefully check for a wiring error within your repairs. Also check wire
bundles for melted insulation and shorts that may be hidden. This secondary damage could have occurred during the fire as wires were burned and faulted. -- JimG 80' CJ-7 258 CID, HEI 4.56 Gears, Lock-Right F&R 35" BFG MT on 15x10 Centerlines D44 Rear, D30 Front. SOA Dana 300 w/4:1 & Currie twin sticks Warn X8000i w/ dual batteries 00' TJ Sport 4.0L, 5sp 4.56 Gears, TrueTrac rear 33" BFG AT on 15x8 Eagle Alloys D35 Rear, D30 Front. 3" Suspension Lift Warn X8000i > Update-- > > Smoke was coming from the new light switch. I unhooked the connector > after seeing wisps of smoke. The ceramic collar that holds the dome > light "on/off" switch became extremely hot. I now suspect a short in > the dome light circuit, but there could be a problem with any circuit > on that switch. > |
Re: Wiring Success...and a New Problem
Carefully check for a wiring error within your repairs. Also check wire
bundles for melted insulation and shorts that may be hidden. This secondary damage could have occurred during the fire as wires were burned and faulted. -- JimG 80' CJ-7 258 CID, HEI 4.56 Gears, Lock-Right F&R 35" BFG MT on 15x10 Centerlines D44 Rear, D30 Front. SOA Dana 300 w/4:1 & Currie twin sticks Warn X8000i w/ dual batteries 00' TJ Sport 4.0L, 5sp 4.56 Gears, TrueTrac rear 33" BFG AT on 15x8 Eagle Alloys D35 Rear, D30 Front. 3" Suspension Lift Warn X8000i > Update-- > > Smoke was coming from the new light switch. I unhooked the connector > after seeing wisps of smoke. The ceramic collar that holds the dome > light "on/off" switch became extremely hot. I now suspect a short in > the dome light circuit, but there could be a problem with any circuit > on that switch. > |
Re: Wiring Success...and a New Problem
Jim:
Thanks. I did it--tracing the wires wherever I could access them, and also checking resistence with the tester on all wiring. I know the switch splice is clean; believer the rest of the wiring to also. I tested again and isolated the tiny emission of smoke to the new headlight switch. The back of the switch gets too hot to touch, especially around the ceramic shield and dome light actuator switch. I have developed a new theory, with the help of an article by Mike D'Ambrogia, lined on the IFSJA website, that the Halogen headlights with which this GW is equipped are at fault. They draw too much power and overheat the switch. I am fairly certain that the 1984 Grand Wagoneer was NOT originally equipped with these much brighter lights. RB |
Re: Wiring Success...and a New Problem
Jim:
Thanks. I did it--tracing the wires wherever I could access them, and also checking resistence with the tester on all wiring. I know the switch splice is clean; believer the rest of the wiring to also. I tested again and isolated the tiny emission of smoke to the new headlight switch. The back of the switch gets too hot to touch, especially around the ceramic shield and dome light actuator switch. I have developed a new theory, with the help of an article by Mike D'Ambrogia, lined on the IFSJA website, that the Halogen headlights with which this GW is equipped are at fault. They draw too much power and overheat the switch. I am fairly certain that the 1984 Grand Wagoneer was NOT originally equipped with these much brighter lights. RB |
Re: Wiring Success...and a New Problem
Jim:
Thanks. I did it--tracing the wires wherever I could access them, and also checking resistence with the tester on all wiring. I know the switch splice is clean; believer the rest of the wiring to also. I tested again and isolated the tiny emission of smoke to the new headlight switch. The back of the switch gets too hot to touch, especially around the ceramic shield and dome light actuator switch. I have developed a new theory, with the help of an article by Mike D'Ambrogia, lined on the IFSJA website, that the Halogen headlights with which this GW is equipped are at fault. They draw too much power and overheat the switch. I am fairly certain that the 1984 Grand Wagoneer was NOT originally equipped with these much brighter lights. RB |
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