Suddenly no more headlights?

rhkcommander · Mar 2, 2020

So I was driving the other night on my new property working the truck, headlights were fine on the way there, needed more light so I pushed the floor switch for brights and the headlights go off, haven't come back.

Turn signals and reverse work. I had one other issue a year or so ago, at night going down a winding pass by Bakers City, hit brights, cruised for a while, sudden darkness on ALL lights, tried the floor switch repeatedly and eventually normal low beams and other lights came back and we limped home.

Is it more likely to be the floor switch, a fuse link, or the light switch?

Truck in question is my signature 1987 F250 standard cab.

Are these parts compatible?

https://shop.broncograveyard.com/mobile/1966-1977-Ford-Bronco-Dimmer-Switch/productinfo/17150/

https://shop.broncograveyard.com/mobile/Headlight-Switch-87-89/productinfo/37137/

I've been meaning to do the relay, is this one good?
https://shop.broncograveyard.com/mo...vy-Duty-Headlight-Harness/productinfo/34805B/

Thanks for any insight on this, I really appreciate it.

chillman88 · Mar 2, 2020

I had a similar experience with my truck. Turns out my high beam switch wasn't bolted down properly and I haven't had it happen again yet.

I'd replace the floor high beam switch if it was me. I believe that directs current to either high or low beams so it probably has failed internally.

That bronco graveyard relay kit is the one I used. No issues other than the relays aren't standard bosch style. That said, I haven't needed to replace them so it's a moot point.

chillman88 · Mar 2, 2020

Actually I misread. I'm not sure what to think of ALL the lights going out. I'd imagine they could have shorted, but then I'd think a fuse should have blown? Very odd.

IDIBRONCO · Mar 2, 2020

chillman88 said:
Actually I misread. I'm not sure what to think of ALL the lights going out.

No you read right the first time. Only the headlights went out. I had that happen to me last summer. My dimmer switch wasn't screwed down tightly to the floor and the wiring plug had wiggled loose from the switch. I plugged it back in and the headlights worked fine. It may not be your problem, but it's a place to start.

Chris Helton · Mar 2, 2020

Clean the corrosion off the dimmer switch mounting bolts, anti-seize and sock it down. Mine did it constantly until I did this. Fixed it.

rhkcommander · Mar 2, 2020

I'll give these all a shot, thanks guys!

Yeah last summer it was ALL lights if I recall , this time it was just headlights not working. I was told something was overheated from running the high beams back then, but I could be wrong on the details.

I was just astounded how it failed, right when I hit the floor switch they went out, and they haven't come back since...

I have bulb holders and bosch relay holders, but a ready-made harness for that cheap is the way I'll go!

chillman88 · Mar 3, 2020

rhkcommander said:
I have bulb holders and bosch relay holders, but a ready-made harness for that cheap is the way I'll go!

In that case buy the harness and in the unlikely event a relay fails just rewire it for the standard relays!

Good luck and keep us updated!

rhkcommander · Mar 9, 2020

It was the foot switch, I pulled the plug and jumped it, voila headlights. Plugged it back in and out with some contact cleaner and the pins' holder popped off.

I took the whole switch out and it had corrosion galore, so I used a file to clean the contacts on both the pinout and the rocker inside and out.

After that and cleaning the grime, reassembly, it worked again! Tha is guys. Next is the relay upgrade. I have pics but I need to get on a pc and shrink them before uploading.

IDIBRONCO · Mar 9, 2020

I've even been in situations where that switch didn't want to switch between high and low beams. I have taken it loose from the floor, turned it upside down and sprayed some lube under the upper moving part. After working it by hand several times, it would work just fine again. Of course, that was while I was a civilian contractor in Iraq where we usually didn't have access to new parts like that. Around here, I'd just replace it with a new one.

jwsfarrier · Mar 9, 2020

Could that Hi/Low beam switch somehow effect the dash lights as well. Just recently, I hit the switch and found out I have no lights at all when trying for Hi beams. I do have the Lo beams working when switching back. Weird thing is I lost all dash lights when this started and they have not come back on. I checked the fuse, all good there. I have installed those relays mentioned earlier . Makes sense to start with that switch. Really sucks not having dash lights or Hi beams

rhkcommander · Mar 9, 2020

It may be real easy to test, remove the rubber floor covering over the switch and you can get to its harness. Center goes to the other two wires to swap between high and low from what I understand. In my switch with playing with it, it looks like its activating a relay, because it returns to rest at the same switch position after being pressed.

I want to say the fuse panel had dash lights with exterior IIRC, but if you have low/dash then the fuse is fine anyway. My guess is the switch on the dash that controls both dimming and headlight on off is bad or corroded.

On some of these old fords you gotta smack the dash, maybe when you kick the switch something elsewhere jiggles? Corrosion everywhere on these 30 year old trucks. My friends blower motor wouldnt turn on until I gave a good whack over the control panel area... if that works, I would open it up and look for shorts and clean the terminals.

jwsfarrier said:
Could that Hi/Low beam switch somehow effect the dash lights as well. Just recently, I hit the switch and found out I have no lights at all when trying for Hi beams. I do have the Lo beams working when switching back. Weird thing is I lost all dash lights when this started and they have not come back on. I checked the fuse, all good there. I have installed those relays mentioned earlier . Makes sense to start checking that switch. Didn't think of that. Really sucks not having dash lights or Hi beams

jwsfarrier · Mar 9, 2020

Thanks for the info. Yeah, I have fixed a few electrical problems with a good whack!lol. I'll check out my headlight switch in the dash next and see if that shows me something.

catbird7 · Mar 10, 2020

Cheap replacement switches, both headlight and dimmer have probably destroyed miles of wiring. Real FORD replacement parts are always your best bet and the member tested relay upgrade is an excellent method for protecting your wiring harness against a possible melt down. I also like using dielectric grease on plug connectors to aid in sealing from moisture and provides a lubricant to make disassembly much easier.

rhkcommander · Mar 10, 2020

Here we go, top picture shows the black press-fit insert that directs power with the white plastic/sprung metal thing. Clean all those contacts and it's good to go! A "toothpick" comes down from the switch head and temporarily pushes the axis to hit the other wire before going back to rest on the normal position. You can reverse this by manipulating the white rotating piece, though I'm not sure why you'd want to do that, or if it could affect anything. Seems like a simple relay switch setup to me, but I haven't chased it all out or looked at any schematics lately.

There was old caked up grease on the inner plastic and spring, cleaned it off and made sure the spring still provided ample pressure. I took the black insert and filed all four points at once, then filed the rotating pieces' points, and then cleaned up the terminals (which weren't done in this picture :angel:

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Suddenly no more headlights?

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