TheSamba.com :: View topic - 1966 Headlight Relay differences and wiring woes...

Mon May 02, 2011 6:52 pm

OK so I'm having trouble wiring my 66' Hi-Lo relay, my turn signal lever, and then some...

I have the wiring diagrams and I have the instructions that came with the new harness...but my Headlight relays are totally different...and the instructions are throwing me off...

Here are the old and new relays:

I am going through a 12V conversion but really stuck on how to wire these things up...

Instructions say:
White Wire: #S Hi-Lo Relay Unit to Fusebox Terminal marked "W". (OK I did that)
Yellow Wire: #54a Hi-Lo Relay Unit to Fusebox terminal "Y". (Problem with that is there is no #54a on either the new or old relay.)
Brown-White from Turn Switch to #S Hi-Lo. (Ok but I'm already using #S with the White Wire...)

And once that is figured out, where does the Brown wire from the turn signal go the flasher???

Here are some other pics just because...

Any help would be so SO appreciated. ](*,)

Mon May 02, 2011 8:42 pm

Oh that is awesome thanks! My relay came with nothing. It was the new wire harness that came with instruction. And this guy came with instructions too: http://www.airheadparts.com/vintage-vw-parts/flash...11953227-b

Thanks Banzai KG!!! That will get me going for now!

Mon May 02, 2011 10:13 pm

This 12V Hi-Lo Headlight Relay Wiring Diagram should be of use to all.

Now where does the brown and white colored wire from the turn signal lever go?

Tue May 03, 2011 10:48 am

So which of these is correct if I have a 66' but am doing a 12 Volt Conversion?

This One?
http://www.oldvolkshome.com/headrelay.pdf
This One?
http://www.oldvolkshome.com/6870turnswitcht1_OVH.pdf

Or either of these 2?

Pic One:

Pic Two:

If Pic One is correct: The brown wire just grounds out?

If Pic Two is correct: Where does the Brown w/White wire go?

Thanks again!

Tue May 03, 2011 1:32 pm

I don't mean to hijack this thread but will a defective dimmer relay cause you to have no headlights? Right now my '69 Ghia has no headlights and I just replaced the headlight switch with a new one and cleaned up all of the ground connections and checked all the wiring and it is good. I'm stumped.

Tue May 03, 2011 6:14 pm

toddb_67 wrote: I don't mean to hijack this thread but will a defective dimmer relay cause you to have no headlights? Right now my '69 Ghia has no headlights and I just replaced the headlight switch with a new one and cleaned up all of the ground connections and checked all the wiring and it is good. I'm stumped.
Only thing I can think of is use a voltmeter and check for around 12v at the headlight socket; if you're not getting 12v from the socket...then check for voltage at the relay. Then the headlight switch, fuse block, etc...

Wed May 04, 2011 6:35 am

This is where I am stumped. I suspect I have a bad headlight switch right out of the box, it is brand new from CIP1. I am getting 12 volts at the #30 connection on the switch but when I pull out the headlight switch I am not getting 12 volts to the #56 on the relay. I tried bypassing the switch and jumping 12 volts straight to the relay and still no lights. The only way I can get the lights to work at all is to bypass all of the relays and switches and just apply 12 volts to directly to the white headlight wires. So I know I have good wiring going to the lights and good grounding, I just can't figure out if I have a bad switch or a bad relay or both?
Any ideas?

Sat May 07, 2011 6:51 am

Can anyone chime in on my dimmer relay issue. I have searched and could not come up with an answer.
My main question at this point is, can a bad dimmer relay cause you to have NO headlights?
I hate to keep throwing parts at this problem. I'm hoping I don't have a bad headlight switch right out of the box! :x

Sat May 07, 2011 7:42 am

toddb_67 wrote: Can anyone chime in on my dimmer relay issue. I have searched and could not come up with an answer.
My main question at this point is, can a bad dimmer relay cause you to have NO headlights?
I hate to keep throwing parts at this problem. I'm hoping I don't have a bad headlight switch right out of the box! :x not likely a bad relay, but possible.most likely an error at headlight switch.(either the switch itself or hookups) I had a brand new (made in china headlight switch ) fail right out of the box. KGPR replaced it no questions asked. 1 click on switch should give parklights, and second click give park and headlights.if you don't have power @ 56 on relay headlight won't work. need to have power from 56 on headlight switch to 56 on relay. a jumper on 56 terminal of relay should give power to 56A or F terminals on relay. it sounds like you might have 2 different issues

Sat May 07, 2011 8:34 am

Yeah, my first thought was that it was both the switch and the relay. The switch is not getting 12V to 56 but is getting it to the park lights and 56b (the dash lights). I tried jumping 12V to the 56 post on the relay and still not headlights, very frustrating! I was hoping someone had a similar issue and could tell me a easy way to test them both but I think I already know my answer, bad switch and bad relay.

Wed Nov 14, 2012 4:34 am

So what is the final verdict on Bluexl's question??

Where do the brown ( or brown and white ) wires go to? Are they just ground?

I just bought a 66 a ghia and will be doing a 12v switch this winter, but am unsure how to handle the headlight switch in the turn signal stalk.

Thanks
Jack

Thu Mar 30, 2023 10:09 am

Hello everyone, I'm new to the forum. I'm in need of some help with my 66 Ghia head lights. My problem is, I can pull light switch halfway out and high beam comes on, on the drivers side, but not on the passenger side, I can pull switch all the way out, and both dimmers comes on. Can anyone tell me why is it that I'm only getting one head lights to come in the first stage of pulling the light switch. Thank you for any assistance. PS. I'm definitely trying to follow the diagram that I bought for the year of the car. 1966 diagram. Thk's again.

Thu Mar 30, 2023 11:01 am

Carr63 wrote: Hello everyone, I'm new to the forum. I'm in need of some help with my 66 Ghia head lights. My problem is, I can pull light switch halfway out and high beam comes on, on the drivers side, but not on the passenger side, I can pull switch all the way out, and both dimmers comes on. Can anyone tell me why is it that I'm only getting one head lights to come in the first stage of pulling the light switch. Thank you for any assistance. PS. I'm definitely trying to follow the diagram that I bought for the year of the car. 1966 diagram. Thk's again.

You should have no headlights at all on the first step out. That should be parking lights only (ie front turn signal lights in static on setting). Your headlights turn on with the switch all the way out, and then the button on your turn signal stalk turns the high beams on/off.

From the owner's manual
https://www.thesamba.com/vw/archives/manuals/8_1965_ghia/8.jpg

You've got something wired incorrectly. Trace through the schematic and see what is hooked up incorrectly. No need to buy wiring diagrams, they're all here on the samba ;)
https://www.thesamba.com/vw/archives/info/wiringghia.php

https://www.thesamba.com/vw/archives/info/wiring/ghia_66_USA.jpg
https://www.thesamba.com/vw/archives/info/wiring/ghia_66_USA_key.jpg

The first step out on the switch engages terminals 57 (front turn signal running lights), 58 (rear running lights), and 58b (gauge backlighting). The 2nd step out engages terminal 56, which connects to the headlight relay, which is activated for high/low beams by the connection at terminal S to the turn signal button.