suncomb1, question for me: I know you use the ohm setting to check a fuse when it's out. Since a positive charge is running thru it when its connected, can that damage the meter?

 

give it a good "tug" if it breaks , its toast and need replace ..
this is the way




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Thanks everyone for the info... and ChipX (my brother!). Haven't had a chance to check it yet tonight, will do in the morning. Wanted to post 1 more picture. This red wire with a black (maybe dark grn) stripe is bundled in with the other half of the FL and attached to a male connector, but nothing is connected to it. Is it possible that's the line for the HL?

 

Yes that can damage a meter if you are on the Ohm scale / mode. Usually the internal fuse will blow first. So open your meter and check / replace the fuse. Put the meter on ohms and test it. If the meter works it should be okay, if it doesn't you need another meter.

 

That could be the wire you are looking for, it sounds like the right color code. The plug should be green. Take your meter, set it to Ohms, put the Black - lead on the terminal in the plug and place the Red + lead, with a piece of wire extenstion, on the terminal with the Red/ Blue wire connected to it, of the headlight relay. If you get a reading, that is the wire that feeds the headlight relay. If it is the correct wire you will need to connect it to the positive terminal of the battery. Be sure you put an inline fuse / circuit breaker in the wire that is large enough to handle the load. Headlights and Hazard Flashers / Horn are powered from this circuit.

 

That was it!!! The red wire! Well, I now know a hell of a lot more about the trucks wiring system than I did over a week ago! Thanks guys for all your help!
Btw... if the fuse for the HLs are set at 20, should I make a fused circuit leading to the positive terminal as well?
Thanks again!

 

Remember, your 4 way hazard circuit is fed from the same power wire so you will have to go bigger on the fuse maybe 30 Amps at the battery + source.