EFI85

Hi guys I know its been a while as my truck has been running great and I've been super busy raising kids . My issue is on my 85 I have serious issues with my headlight harness from the combo switch on the column all the way over to the fuse box . I'm not sure what to do . I'm thinking a new combo switch and trying to find the harness is my best bet . I will make better grounds when I replace it since there seems to be an issue of the harness holding up to the ground load of the 2 headlights . Here are my questions

1. have any of you had this issue
2. if so how did you remedy it
3. how do you get the fuse box off of the kick panel on the drivers side so I can start digging into those wires.

thefishguy77

iTrader: (1)

The full power of the headlights is run through the stock. Several people on here have fixed this problem. I cant remember if its just adding a relay or what not. If you have melted wires then your probably going to need to tear it out and start with good wire. I am sure someone with more electrical expertise than I will chime in.

thefishguy77

iTrader: (1)

@RAD4Runner

RAD4Runner

As far as I have seen, the headlight wires run between headlights, engine compartment fuse block / headlight relay and dimmer combo stalk switch.
However, you are in the best position to find out exactly what parts you need to access.
Fix:
1) If wires are melted, need to find out why, fix that and replace wires. Need to find where they shorted to ground. Only you can physically trace wires and find out.
2) Take voltage / resistance readings according to this post. Report back.
3) Once the circuit and lights are working, research "H4 conversion harness" to take the high current load of lights off the dimmer-combo stalk switch and shorten the path of current to bulbs. Google "4Crawler convoluted path".

IF it's like my 1986, the fuse block behind drivers kick panel has one screw (10-mm head). Take that off, Then look for a push tap somewhere on top and in the back of the plastic panel to completely release from body metal.

EFI85

Ok so I did a bunch of investigating and the melting went pretty far back into the harness looks like I'm gonna be taking the dash and half the cab apart to replace all of it . I have a feeling its been this way for many years as in like before I got the truck since I have never ever smelled anything burning . Its looking like I will need to start with a good used harness I'm sure I could replace all the wires but it would take a lot and finding the replacement plugs and all of that would not be easy and I'd really like the colors to be correct and don't want to try to source all the wires in different colors to keep it correct . Super bummed by this mess but I'll get it sorted out . As for now I tested everything and there is no more power going into the combo switch from the lights and so I'm pretty sure I;m not at risk of a fire so IM GOING HUNTING !!!