Thank you, wonder if I can swap them side to side (left to right, right to left) to see if the problem moves. That is what is killing me on this, I cannot get the issue to move somewhere else.

Thank you. I just might buy a set just to have in the garage.

 

There are no headlight relays for low/high beams.

Next item on the HIT LIST appears to be the Column Switch Assembly, it is literally the only damn thing that is left that I haven't checked/replaced.

Today I was able to get the low beam on for more than a few seconds (5 or more minutes), so I decided to try to make it fail and hit the high beams switch and the low beam went out and the high beam did not come on. After that, I couldn't get it to come on again.

To change out the column switch assembly, it requires removal of the steering wheel (AIR BAG and all) just to get at it, then it is $275 from Pelican parts. Ugh!

 

You have HID, when you switch on high beam, it doesn't turn off the low beam. It activate a switch to move a cover in the headlight assembly out of the way. So it shouldn't be your stalk. If it is, then both side would go out.

don't know what you mean by no headlight relay but part number is 141-951-253-B

 

Stalk? You mean the column switch assy?

Just walked out and turned on the accessory without turning on the car. The driver headlight is still not coming on and if I hit the highbeams, the driver highbeam does not come on either and I can hear a "switch" trying to work.

The Passenger side works perfectly during the above test.

Now, keep in mind the following: (1) headlamp is fine (2) ballast is fine (3) headlight switch is new (4) the headlamp does, on occasion, comes on

 

Hmm. No high beam either? What you hear is probably the "shade" moving out of the way. Unless it's coming from under your dash, then you have a bad relay.

 

Under the dash, there are no less than 10 relays (all of which are labeled the same). Does anyone have the relay layout? And what each does? And can they simply be swapped amongst each other?

 

I had the same exact thing.

loosen the headlight cam, then tighten. fixed mine 3 years ago and it hasn't come back.

 

Headlight cam?

Are you talking about the single shaft that passes from the front of the headlamp assy to the back near where you put the bulb in?

OR are you talking about the cam that locks the headlamp in place?

 

More "great" news. Today, swapped two different headlamp assemblies in place of mine and both fired up immediately like they should.

So, this nulls out anything inside the car and isolates the issue to inside my headlamp assembly and it cannot be the ballast or headlight itself because those have been swapped out and the problem remained.

So, what the Hell else is there inside the headlamp assembly itself? Looking over the drawings, I see nothing. It has to be a lose wire or bad ground. Does anyone have a wiring diagram of the inside of the actual headlamp assembly?

 

Could your headlights be corroded? Can you get it apart enough to see if you have any corrosion on the terminals or wiring?

 

In regard to all terminals, each has been cleaned and then sprayed with contact cleaner and allowed to dry prior to any testing.

I'm diving in to the assembly tomorrow when I get home from work, after today's wonderful news, I didn't have the heart. It is mind blowing that after all of this troubleshooting, it is a lose wire or bad ground inside the wiring loom within the headlamp assembly itself. The more ironic part is that it works from time-to-time with no change in vehicle dynamic (meaning, the car is stable and only at idle) and I get a variety of symptoms.

 

This this case, check your bulb.

 

Oh God, I wish it were that easy of a fix. First step was to replace the bulb and that was many logged T/S hours ago.

Additionally, the bulb works occasionally, when it feels like it and the "bug/gremlin" is not present.

 

that's why it might be your bulb that is burned out.

 

Nope, it's not the bulb, ballast, switch, a relay, high beam/low beam switch on the column... it is IN the headlamp assembly.

Today, after Thanksgiving meal, I wandered out to the garage for some more troubleshooting. I put the headlamp on my work bench and extended it again with the 10 foot leads that I made.

This time, instead of connecting the wires from the car to pins 11 & 12 (PICTURE #1) to the normal male connector, I bypassed the connector and went directly to the ballast input (PICTURE #2), started the car, turned on the switch and the low beam comes on and works PERFECTLY 10 times in a row.

So, the issue is somewhere between pin 11/12 and where it enters the input side of the ballast.

Is there ANYONE that services headlamp assemblies? This thing internally is pretty complex and getting to the backside of the connector that pins 11/12 are on is tough because of where it physically is.