Lights Out When High Beams Are Turned On...

[southernman]

Why do you think it's a dead short if no fuses are blowing?
 I forget what kind of car this is,.. MK1s have a couple 10 post plugs near the firewall,.. maybe one of those is corroded.

I know it's a dead short because I can feel the temperature rise on the wires when I engage the high beam switch. If I were to leave the switch connection in place, it would blow a fuse - or melt some wires. I'm switching back to low beam for each test, to prevent a melt down. I disclosed that above.

The weather here's been really crappy lately, and I haven't had time to get back to it. It's supposed to clear up over the next couple days so I hope to get some to work on it. Since it's not my primary ride, I'm able to back-burner it from time to time.

Again, guys, thanks for posting the suggestions and I will be sure to check them out. just haven't had time to get back on it.

S

[CRSMP5]

So how did the wire joint look that i spoke of?? Dude, it makes things get hot, im serious

[southernman]

Finally figured it out guys...

I finally pulled the dash yesterday and was able to determine the problem was on the feed-side of the high-beam switch (i.e. even after pulling the instrument panel, and disconnecting it, my wires were still heating up and the cyclic sound was still there).

Just as I was anticipating pulling the complete dash so I could do a full trace, I saw the culprit.

It was the main feed wire from the headlight switch (white wire) that appeared to the culprit, so that's where I started.

Turns out I had replaced the steering coupler several months ago and remember the problem starting after that. This lead me to think one of the steering columns electrical components went bad, since I didn't drive the truck for a few weeks after the repair. So, here we go again...

I replace the relays; then the turn signal switch; then the wiper switch (if you're pulling the steering wheel...); and then began to get "lost" in the whole process. Lack of time etc, kept me from finishing it, but what really threw me was the fact the clock had stopped working about the same time.

Did the deep-dive yesterday; the white feed-wire from the headlight switch (the one going into the connector on the dimmer switch) had gotten pinched between the bolt and column from when I had previously made the repair. The PAIN here: entirely self-inflicted...

Just thought you guys would like to know, so I'm on my way now to get the inspection done and restore my little heap's "primary" status as daily driver.

Thanks for all the feedback guys. Your participation makes this a fun site for me. Now, stay tuned as I post some of the mods I've done to my truck over the past several months. I guarantee you're gonna like 'em.

Southernman