Originally Posted by crispyboy
Your making that into one fine looking pickup - good work.
You may want to dump the flex fan for a factory clutch fan setup if your doing mostly on-road driving. I remember flex fans being noisy and won't help your fuel efficiency.
No doubt, it's on the list of things I want to get done. Either a clutched fan or an electric one. Either way that wood chipper needs to go
Anyway I need to update to here goes.
After my close calls I went home and got a good night's sleep.
I came back the next day rested,focused and determined.
Detective work on the front harness started in earnest.
How hard could it be right?
If you you watched my video I posted a link to "Electric Voodoo" I was demonstrating a wierd grounding issue I was facing. Thinking this issue and the non-op headlights were related I dug right in.
What I discovered was the headlights and the turn signal/markers are "seperate" systems in as much as one will continue to function after the other fails. And turns out this issue and the headlamp one was not related.
Now the Signal/markers are interesting in how they are wired. When the running lights are on both the low element and the high element in the turn signal bulb are energized and the side marker as well. The Marker and the High element are in series, with only enough power to light the lower amp bulp, actually using the high element to comlete the circuit. When the signal is activated it switches the ground, cutting the marker off and allowing the high element to light and the marker "blink".
Isnt Ohms law fun?
Pretty slick imo.
I eliminated the crusty turn signal plugs that go up into the face panel in hopes of removing unwanted resistance and to get a more reliable connection to the socket. I was trying to reuse the wanky junk sockets that were original to the jeep. And after cutting and soldering the new connections I turned my attention to the socket. I say with a wire brust and a top post terminal brush and made the insides of that socket shine like new. My best result was a flickering side marker due to a poor connection in the socket with the bulb ( part of that curcuit remember? )
I was willing to live with this result, not happy with it but it was better than what I had, at least it kinda worked. ( Sounds like a Jeep motto )
After getting the markers and signals functional ( sorta ) I started in on the headlamps.
Almost instantly I had a terminal snap off in my hand.
Me being the cheap bastage that I am.. I soldered the puppy right back on!
Sadly that didnt magically fix my headlight issue.. the shop didnt fill with a holy light and angels didnt sing.. darn
My sacrificial test light ( yes the one the fan ate ) told me I had a tiny trickle of power coming through on the low beam circuit, and reversing the test light to ground to the positive terminal of the battery told me my grounds were solid. So I went upstream.
The fact the markers and whatnot were getting power told me the headlight switch was getting power and the source was a common one so I concentrated on just the headlamp circuit.
Next stop was the dimmer..
It looks like the terminal hot way hot when the dimmer failed.
I didnt get a good pic of it but it looked like it had been sitting under water for years.. green, crusty and needing to go away.
I wanna thank Bill for the suggestion, He told me to just go ahead and buy a new dimmer switch, I'll probably need it.. So just off the frame of that second pic was a brand new one sitting in the box. Two screws and a plug and I had low beams... But still no high beams.
Test light said.. ( yes that one ) that I was getting good power through both leads and it was switching properly.. but the lamps were not lighting..
Reluctanty I pulled a head lamp and using the battery charger I started testing the lamp..
NO high beam.. Element must have been burned out. okay new lamp needed. Tested the other one.. same stinkin thing.. How in the world could both high beams blow out? Maybe that's what cooked the plug and the whole system blew? Who knows. But it's something to watch out for.
I will be going back and dunking that whole switch in liquid tape to seal it up.
There's also a hole about 6 inches above the switch just below the fuse box where PO's were running mass wires through the firewall.. I think that needs to go too.. you don't need a hole you can stick your thumb into for wires..
I'm about to button up the front end after getting new lights, and having everything I should have, nice and bright.
And I'm clearing out some extra bits off my tool cart when I pick up a turn signal socket off of a recently scrapped 95 Tahoe (I keep stuff remember?)
I'm turning it over in my hand.. then pick up one of the jeep's front turn signal housing.. I stick it in and it fits and locks in!! HOLY CRAP!!
Here's a side by side comparison.
It doesnt exactly LOCK into place but it fits nice and snug and the foam gasket on the plug keeps it firmly in place.
It also uses the same bulb the Jeep uses so there isnt any voltage issues.
Here's how you wire it.
Black to black, that's your ground.
on this one I had a brown and a light blue lead.
So brown to white
and Light blue to white with the black stripe.
But ALWAYS black to black and you can check yourself by turning on your running lights.
If the high element just barely lights up you've got them backwards.
Connected and shrink tubing
And these are used on a TON of GM cars/trucks easily replaced from a parts store and really easy to wire up.
I call that a win on all fronts.
Here's the other side..
I would also like to point out that me being a pack rat paid off again.. I found these buckets with unbroken tabs in my pile!
The ones I removed were held in by RTV.
And let there be light dangint!
Nice and bright and no flickering markers!
So I buttoned up the front end and moved to the back.
My tail lights and running lights worked fine but I had to take them apart to fish out my side markers.
What came off vs what went back on.. Again bits from the parts pile.
These I think came off a 77 f-100 I had. Those side markers were in use all through those years and were on the econoline vans up into the 90's.
Now this side was a bit of a pain.. notice the lack of holes?
Bondo. there was a skim coat of filler on this panel. I used my pick tool and poked them out from the inside.
Meanwhile the Side marker and I would play peek-a-boo for a little while.. usually dropping back into the bedside only after putting the tail light back in..
I fixed it wagon.. pull back through NOW you little..
So I got the back end buttoned up and even installed a plate light! (didnt have one)
Cut out a ton of butchered and frayed trailer wiring and got some lunch.
Now here's where my wiring OCD kicks in..
I was probing with my meter and noticed a HUGE voltage drop between the battery and they body, and between the battery and the starter solenoid.
I condiser 2 volts to the body and 1.4 volts to the starter huge. Who wouldnt right?
Who does this??
At some point I suppose the ground lead broke.. so bubba just took the smalles wire he could find and duct taped it on.. ugh.. but one thing at a time..
Here's where I got medieval on the battery terminals..
Cut cleaned and tinned the wires..
Had to put a lot of heat into that wire to properly tin it as evidenced by the shrink tube further down the wire.