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'91 XJ : Headlights go out then come back on ??


 
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OldFart
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Joined: 30 Oct 2007
Location: Florence, Colorado

PostPosted: Wed Oct 31, 2007 7:00 pm    Post subject: '91 XJ : Headlights go out then come back on ?? Reply with quote

Hi all
Headlights acting up. They turn on fine..then..after 3 to 5 minutes... just black out, including dash lights... for maybe 5 to 20 seconds.. then come back on (then off, then on, etc). It seems to be heat related ? (It happens quicker on brights than on dims) Is there a thermal breaker ? Could it be overheating/weak relay ?. Already replaced switch with new. No change. New, strong battery. Charging system fine. Lights seem normal brightness when on. Just running parking lights does not do this. All other electrical operates fine.
Does not have "auto" headlight type switch/function.
Any ideas ??
Thanks in advance.
Kit ( OldFart)
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tag
Member


Joined: 16 Jul 2006
Location: leeds yorkshire england

PostPosted: Thu Nov 01, 2007 10:26 am    Post subject: Reply with quote

Hmm, you will have a relay that turns the h/lights off , maybe it's acting up! it turns them off if you have locked the car and left the lights on . hope this helps..............
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88WOWJ
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Joined: 12 Aug 2006
Location: Hinesville Ga

PostPosted: Thu Nov 01, 2007 1:32 pm    Post subject: Headlights go out Reply with quote

Check the wiring at the dimmer switch on the column and the wiring at
the headlight switch. They are prone for wires to burn.
My 1988 has done both
If I recall the problem was at the dimmer switch connector.
A hot wire had burned its terminal end. Replaced the terminal end.
_________________
1988 Wagoneer Limited XJ Tellico Tested
Rocklizards panels, Tomken rear bumper and front Tow brackets, Rocket air intake, 2 inch lift,
30x950x15, 1991 coolant system with electric fans, 8,000 mile marker winch
1991 Cherokee Limited
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OldFart
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Joined: 30 Oct 2007
Location: Florence, Colorado

PostPosted: Fri Nov 02, 2007 4:22 pm    Post subject: Thanks Reply with quote

Thanks
Will look at this week-end.
All suggestions welcome and needed. LOL
Does anyone happen to know where the relay is located ?
The dimmer switch should be pretty straight forward ? Just take cover and everything off ?
thanks again
Kit (OldFart)
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tag
Member


Joined: 16 Jul 2006
Location: leeds yorkshire england

PostPosted: Sat Nov 03, 2007 7:53 am    Post subject: Reply with quote

Sorry mate been trying to find my service manual disc to have a look for you but no joy at the mo, but if i do i'll let you know....
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dizzymac
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Joined: 06 Aug 2005
Location: New Hampshire

PostPosted: Wed Nov 07, 2007 5:59 pm    Post subject: Reply with quote

Check your harness connector under the ECU too. They corrode really bad and cause a bad connection= intermittent or no lights.
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djgrayxj
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Joined: 26 Sep 2007
Location: Southern California

PostPosted: Thu Nov 08, 2007 6:59 am    Post subject: Reply with quote

You may have a short some place in your lighting circuit causing the thermal [Fuse] breaker to cycle. This will be a metal looking object located in your main fuse block; it will be ID as headlights. If you locate this thermal breaker and use a test light one side will always be hot, the other side will go out every time your lights go out. If this happens this circuit is drawing too much current. Possible caused by a bad connection, but most likely caused by a short in your lighting circuit. Also rarely but possible the thermal breaker has become week a opening even though there is no problem, only check for this is to by a replacement of equal rating and replace it. If problem is still there then you can use the breaker in the test described in the following web sight test procedure. Hope this info. Will be of some help.
Web Sight:
http://books.google.com/books?id=lu0XM3keihoC&pg=PA77&dq=gauss+gauge&sig=xu5SEva8intplb4KFM6__T6qHkc
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djgrayxj
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Joined: 26 Sep 2007
Location: Southern California

PostPosted: Thu Nov 08, 2007 7:16 am    Post subject: Reply with quote

Opps
Corection
Also rarely but possible the thermal breaker has become week
a (and) opening even though there is no problem[/b]
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OldFart
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Joined: 30 Oct 2007
Location: Florence, Colorado

PostPosted: Mon Nov 12, 2007 8:00 pm    Post subject: Thanks for ideas Reply with quote

Could not find the source of problem.... but ....
I built a heavy duty new harness for headlights with separate relays for high & low beams....... with the original wires that went to the lights used to trigger the relays & new harness... removing most of the load from the lighting system..... Fixed the problem.. but... still do not know the source of the issue.
A weak thermal breaker ... as you mentioned... seems the most logical.

Very interesting...now.... When I turn out the headlights (at original headlight switch)... when set on "brights" they go out instantly...but... when on dims.. they do not turn off until clicking bright/dimmer switch or turn off ignition switch ????? Perhaps some kind of lack of feed-back to the "delay-timer-off" module ??? seems very strange. LOL
Ideas ?
thanks again for the help and ideas
Kit (Old Fart)
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tag
Member


Joined: 16 Jul 2006
Location: leeds yorkshire england

PostPosted: Wed Nov 14, 2007 11:47 am    Post subject: Reply with quote

found this DELAY FUNCTION INOPERATIVE
(1) Ensure headlamps operate before proceeding.
(2) Remove, inspect and test the HDLP delay 10
amp fuse in junction box. Replace if defective.
(3) With the key off and the connector disconnected,
measure the resistance from the delay module
terminal 4 to vehicle body ground. The ohmmeter
should indicate zero ohms. If not, repair the open circuit
in the wire harness to vehicle body ground.
(4) With the key on measure the voltage between
the delay module terminal 8 and vehicle body
ground. The voltmeter should indicate battery voltage.
If not, repair the open circuit in the wire harness
from ignition switch to HDLP delay module.
(5) Turn headlamps on and measure voltage at terminal
6. The voltmete should indicate battery voltage.
If not repair open circuit between L2 and HDLP
delay module.
(6) Measure the voltage between the delay module
terminal 2 and vehicle body ground. The voltmeter
should indicate battery voltage. If not, repair the
open circuit in the wire harness to the HDLP fuse in
the PDC.
(7) If steps 1 through 6 prove out good, replace
headlamp delay module. hope this helps...........cya
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dizzymac
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Joined: 06 Aug 2005
Location: New Hampshire

PostPosted: Sat Nov 17, 2007 2:13 pm    Post subject: Reply with quote

http://www.go.jeep-xj.info/HowtoHeadlightLoom.htm
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OldFart
Member


Joined: 30 Oct 2007
Location: Florence, Colorado

PostPosted: Mon Dec 10, 2007 10:37 pm    Post subject: thanks for all the ideas Reply with quote

I built a new harness with new lamp sockets and 2 new 30 amp Relays (one relay each for dims and highs) (10 gauge wire from battery (through new multi fuse block) to the relays... then 2 x 12 gauge wire from each relay ( one to each lamp). Used the original wires from the original sockets to trigger the relays. Works perfect... and.... WAY brighter. Then I switched lamps out with "Silverstars". Excellent.
Still don't know what the initial problem was ??? LOL. Perhaps cumulative resistance on an old / borderline system ?
Thanks again for the ideas.
Kit (OldFart)
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uvaldetxj
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Joined: 11 Aug 2008

PostPosted: Tue Aug 12, 2008 12:33 am    Post subject: Headlights Reply with quote

Have your ignition switch checked out, my electrical started messing up a few summers back and that was the source. There's a little plug on it that usually melts the plastic and disrupts everything. Try wiggling wires and messing with plugs in that area.
_________________
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4 Inch Bastard
33 BFG MT
14,XXX
Stock Everything Else.
1987 XJ 2 Door-Chopped Top
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33 BFG MT
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nasoj007
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Joined: 27 Sep 2008
Location: Saint John, NB, Canada

PostPosted: Sat Nov 15, 2008 9:38 am    Post subject: Reply with quote

I had a Thunderbird that did the exact same thing and it turned out to be the switch. I don't know if it's the same in the Jeep but in the Ford there is a relay in the switch that goes bad, overheats and causes the lights to go out until it cools a bit. A $25 switch later and the problem was solved.
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