Electrical help needed-1981 rabbit caddy

[doonboggle]

Have been struggling with this for quite a while ... so am calling a defeat ... and need help please.

The illumination lites of my inst. cluster do not work now after repairing the odometer wheel that was cracked.  After reinstalling the cluster, noticed the circuit mylar 'sheet' was getting chewed up ... and the illumination lites problem, so switched it with one of my spares.  This replacement comes from a car that had the upshift option; but since the caddy does not have this feature, presumed no effect.

Still no lites.

Checked bulbs by jumper to battery feed ... using copper circuit lines #3 & #4 of the 'sheet' ... which is from the battery power and ground connections.
OK there ... lites coming on.

Tested for continuity from cluster feed plug #6 (gry/blue in harness wiring), between plug and where it plugs into the headlite switch.
OK there also.

Checked fuse in fuse block.  
OK there also.

#6, (gry/blue harness wiring) according to the rabbit pickup +diesel schematic I have, also goes to the 'X' terminal in the flasher switch.  Have not messed with it, as I don't forsee that being a problem.
#6 then goes on down to the headlite switch #2 terminal ... which I listed above.

#3 of the mylar sheet (red/gry in harness wiring) also is connected to terminal #4 of what appears to be another plug at the bottom of the schematic ... with description not listed ... but it has total of 12 connections.
It also feeds off of, or into (I'm not an expert) ... a red/gry line that goes to a 15amp fuse feeding off of 30-1.  

Any idea which fuse this is .... and or other suggestions .... PLEASE.
TIA

[theman53]

I have no clue on electric stuff in these cars. That being said the only thing that I could for see is the new cluster is bad. Try just putting power to the lights to see if they work.

[doonboggle]

Been there ... done that ...
"Checked bulbs by jumper to battery feed ... using copper circuit lines #3 & #4 of the 'sheet' ... which is from the battery power and ground connections.
OK there ... lites coming on."

I have no clue on electric stuff in these cars. That being said the only thing that I could for see is the new cluster is bad. Try just putting power to the lights to see if they work.

[rallydiesel]

Maybe try a new headlight switch? 

[maxfax]

Finally got my bentley back..  Lemme see if I can help at all...

(Rambling out loud)

From the head light switch there is the gy/bl wire which you had mentioned..   That is the one that powers all the instrument panel lights..  Ashtray, cluster, radio, AND the flasher switch..  From the head light switch it leads to a 4 amp fuse (#5 in the panel)  From the fuse panel (still a gy/bl wire) it branches out to all the dash lights..  For the cluster it leads to the #6 terminal in the plug..     

The lights in the cluster ground though pin 5 (black or brown wire)

Does your ashtray or hazard switch light up?

[doonboggle]

The only difference from what you are saying, to what I have on my 'sticky' pickup schematic ( http://volkswagenownersclub.com/vw/showthread.php/21294-Wiring-schematic-for-81-84-rabbit-caddy-pickup) is that it's ground in #7 rather than #5.

Regarding observing the flasher or cigerate lites ... did not do that as of yet.  Thought of it late today so will do tomorrow morning.

I have continuity with the gry/blu wire from terminal #2 on the switch up to terminal #6 of the cluster harness plug ... but with cluster plugged in and lites on (today), still no illumination.  Bulbs were verified as OK by jumper of battery to cluster plugs #3 & #4 last nite.

Finally got my bentley back..  Lemme see if I can help at all...

(Rambling out loud)

From the head light switch there is the gy/bl wire which you had mentioned..   That is the one that powers all the instrument panel lights..  Ashtray, cluster, radio, AND the flasher switch..  From the head light switch it leads to a 4 amp fuse (#5 in the panel)  From the fuse panel (still a gy/bl wire) it branches out to all the dash lights..  For the cluster it leads to the #6 terminal in the plug..     

The lights in the cluster ground though pin 5 (black or brown wire)

Does your ashtray or hazard switch light up?

[theman53]

well since you jumped the cluster and it worked try jumping the blue/grey wire. If there is no light then at least you will know what is up there. If it lights up the next bet being headlight switch?

[maxfax]

I just grabbed a cluster to verify, pin #7 is the ground.. I was looking at the plug bass ackwards..  

Since you have continuity from the switch to the cluster that will rule out fuse and wiring..   Did you check for actual 12v power at the switch??  

One other thing, I know this sounds simple (but I have done this  ) do you have the knob on the switch turned clockwise so that the lights aren't dimmed?

[doonboggle]

Got my problem solved ... I think.  And feel like a 'do-do' ... PARTLY.
Appears to be the h/l switch.  I realize this is one of the 'first items' to check, which I did by clearing up the burnt plug shoulder ... and then rehooked up everything.  Continuity was there from plug to plug of cluster ... and lights came on A-OK .  So everything seemed to be kopo-setic .... but still no illumination lights.  Checked and rechecked EVERYTHING 3-4 times ... as late as today.

Finally, even though the switch 'seemed' to be OK ... since it was lighting the headlights OK ... I recalled that I had a spare somewhere ... and dug it out.

Plugged it in and VOILA ... had lights.  This tells me that there is an internal connection of the switch that is defective ... apparently.

Said 'partly' before because the spare is defective in the area of pulling the shaft out with the little button on the bottom.  Just won't let go ... so somehow even that part is defective in the spare.  Have another one coming from rockauto.

Thanks for all the help !!!

[maxfax]

Glad you got it worked out...  The part of the switch that dims the dash lights can be troublesome.. It's the equivelent of a spring sliding over a contact afterall..   And I have had them show continuity, but once there is a load on it nothing works..