Headlight Trouble (Electrical Question)

[SSTJ]

My '97 SE has the pull-out headlight switch. The stalk in the steering column controls the low beams (default) vs high beams, and of course the turn signal.

I have the stock wiring harness, and have had the Toyota headlights described here and here for over a year.

Everything works except for low beams, which work only 50% of the time lately.

Things I've checked:

• Good voltage at the headlights when lights work.
• No voltage at the headlights when lights don't work.
• Clean grounds at headlights, and between battery, tub, and block.
• Tried swapping out the steering column stalk with a replacement.

Eager to hear others' thoughts.

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Solution: I installed a new headlight switch.

• Tried the Dorman 901-264. It arrived damaged, and I didn't like the feel of slinky/spring dimmer. It also didn't have a grounding pin.
• Went with the Standard Motor DS357.

 

[Mitchrb1]

I have a 98 but same setup. The only time I had an issue with the lights not working was before the Toyota lights install but, it was the pull out stalk that was the issue. I went with the Duralast at AutoZone Dorman - OE Solutions Headlight Switch 901-264

 

[KennethS]

I have a 98 but same setup. The only time I had an issue with the lights not working was before the Toyota lights install but, it was the pull out stalk that was the issue. I went with the Duralast at AutoZone Dorman - OE Solutions Headlight Switch 901-264

Same here, it was the headlight switch in the dash. The plastic for the wiring harness connector was melted and a couple of contacts were burned. - this is the main reason I went with the Toyota wiring harness kit. Same as above, a new headlight switch fixed it.

 

[SSTJ]

I have a 98 but same setup. The only time I had an issue with the lights not working was before the Toyota lights install but, it was the pull out stalk that was the issue. I went with the Duralast at AutoZone Dorman - OE Solutions Headlight Switch 901-264

Same here, it was the headlight switch in the dash. The plastic for the wiring harness connector was melted and a couple of contacts were burned. - this is the main reason I went with the Toyota wiring harness kit. Same as above, a new headlight switch fixed it.

Thanks both. In your cases, did you still have high beams, as I do? I haven't studied the wiring diagrams yet, but I would have thought that a faulty pull-out switch would also interfere with my high beams.

@Mitchrb1 @KennethS

 

[Steel City 06]

I’m not familiar with the old setup, but I seem to recall that the newer switches activate the high beams separately from the low.

Meaning if you have low beams on and you flip to high beams, the low beam circuit de-energizes. You could mess with this and hold the switch at a very specific position to energize both simultaneously and get much brighter light than high or low beams alone.

Perhaps that is related to the failure here? Not sure how the Toyota lights are intended to operate, i.e., if they want high beam circuit only for high beams or high+low for high beams.

Perhaps it is failing to re-energize the low beam circuit.

 

[KennethS]

Thanks both. In your cases, did you still have high beams, as I do?

From what I recall, yes. The low beams were flickering while driving then went out. Switching high beam / low beam / high beam / low beam brought them back at first, then the low wouldn't come back on and I drove the rest of the way home with the 100W high beams, hoping no LEO would see me.

I thought the problem was with the high beam column stalk so I changed it. That didn’t correct the issue so I replaced the headlight switch and that is when I found the overheated harness plug.

 

[SSTJ]

Thanks again. I put in a new switch, so hopefully that resolves it.

 

[ColoJeep]

Thanks again. I put in a new switch, so hopefully that resolves it.

On my 99 the switch was an issue when it got cold . only running lights , no headlights . Same issue on a 98 TJ and a 94 XJ . replacing the switch fixed them all .