Headlights tripping out

[AlexTheBug]

Hey guys -- been struggling with my headlights for my '68 beetle.

Not too long ago, they worked fine. Then I started noticing that they would turn on and off while driving. When the headlights turned off, the blue high beam indicator would turn on, but the high beams themselves were not actually on. Sometimes, just the left side would stay on and the right side would go out -- and the high beam indicator light would come on. I also found that they would go back to normal if I slightly pushed in the switch a bit. I was able to get by with that for a while -- finding just the right spot on the switch to get the headlights to work correctly.

I should mention that the high beams were working fine all along -- when I turn them on, they always came on and the indicator showed appropriately. Similarly, the running lights always worked correctly.

Finally my little fix stopped working and no matter what I did with the switch, only one headlight (or none) would turn on, and the blue high beam indicator was always on when I engaged the headlights.

I replaced the switch, going from the original '68 switch to a '71 switch from JBugs with the "X" terminal. I dutifully jumped power from the 30 terminal to the X to power the headlights. At first, it worked correctly. But then, as I was driving away, the issue came back -- one headlight, blue HB indicator.

I've checked all of the fuses. I've fiddled with the wires (essentially leaving everything in place). Should I try replacing the relay? Other ideas?

[Bruce]

I bet the switch is loose in the dash. Or the switch is falling apart.
_________________

[bsairhead]

[VW_Jimbo]

You lost a ground path and the circuit has found a new path through the high beam dash bulb. That would be my guess.

Grounds good at the bulbs? Does your dimmer switch have clean contacts? Wiring in good shape? How about the wiring and connector at the bulbs?
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[AlexTheBug]

The switch is good. It's brand new and seated just fine.

I'm gonna try VW_Jimbo's suggestion. Last night as I was driving, it kept going back and forth between working and doing the high beam thing -- every time I hit a good bump in the road. Or when I toggled the high beams on and off. VW_Jimbo's idea makes a lot of sense to me cuz it seems to be some sort of loose connection -- perhaps at the lights cuz they're so affected by the bumps in the road? Grounds make sense.

[VW_Jimbo]

[ashman40]

I'm wondering if your fuse box is miswired? Here is a simplified diagram from Speedy Jim's site showing how the headlights circuits work.

Note how the blue high beam indicator wire comes off one of the high beam fuses.
Note how the single white wire from the headlight dimmer relay powers two linked fuses at the fuse box and the output wires are white. Take a closer look at your fuse box in the trunk. You should see a single white wire coming off the flasher relay connecting to the INPUT side of fuse#3 where a brass bar links fuse #3 and #4 together. This way this one white wire powers both headlight fuses/filaments.

Test: When you have the situation where the high beam indicator on the speedometer is ON but the high beams are not... get to the trunk side of the fuse box and ID which fuse (#4?) has the blue/white indicator wire AND the white high beam output wire. Disconnect the white output wire. This disconnects the headlight from the fuse box. Does the high beam indicator lamp go out? This suggests the indicator is being power from the headlight rather than the dimmer relay.
Take a VM or test lamp and confirm each of the four headlight fuses are powered in pairs when the headlights are ON in high and low positions. The two yellow wire fuses are powered when low beams are ON. Two white wire fuses are powered when high beams are ON.

Swap fuses. The fuse conductors may be broken and only being held in place by the tension of the clips holding the fuses in place. Physically remove the fuses and check them. They don't always fail by melting in the middle.

_________________
AshMan40
---------------------------
'67 Beetle #1 {project car that never made it to the road }
'75 Beetle 1200LS (RHD Japan model) {junked due to frame rot}
'67 Beetle #2 {2019 project car - Wish me luck!}

[AlexTheBug]

Fun update -- it was just a loose ground by the headlight. Kinda anti-climactic really. But thank you all for your help! Saved me $$ from taking it to the mechanic.

[Cusser]

[gt1953]

While you are at it check all of the grounds....clean them up bright and shiny...fuse holder also.
_________________
Volkswagen: We tune what we drive.
Numbers Matching VW's are getting harder to find. Source out the most Stock vehicle and keep that way. You will be glad you did.

72 type 1
72 Squareback
({59 Euro bug, 62, 63, 67, 68, 69, 73 type ones 68 & 69 type two, 68 Ghia all sold})

[heimlich]

Something is loose. Open the hood at night and wiggle things around. You'll find it.
_________________
www.vwnos.com [email protected]
Classic Brands. Classic Quality.
Not all parts are made the same. NOS OE/OEM parts made mainly in West Germany, Early Germany, and Early Brazil are where VW produced the best quality parts and best fitting products.
5% Off your order with coupon code: 5%OFF
Restored Distributors Available (<--Click here)