1970 Karmann Ghia flasher conversion

[Altema]

Thought I'd post this although I did my conversion last year. Please note that this is for the 1970 model, so you will need to check variations in wiring from year to year.

I had a problem with the turn signals on the Karmann Ghia going out on occasion. If the signals were on for a long time, like waiting to make a turn in a traffic jam, they would not work for a while afterwards. The dash indicator would come on solid, and the outside lights would not come on at all, which meant I had to resort to hand signals. The old flasher had two internal relays and appeared to have been modified for the KG’s single indicator in the speedometer. I pulled it apart and found a bad capacitor, which I replaced with the closest value available (100u, 25v). It works fine now, but that left me wondering what I would do if it needed replacement. A quick stop at a VW dealer revealed that they cannot get that part anymore. The local NAPA store never saw anything like that before, but they did let me dig around in their collection of random flashers. There was one that had similar connections, but since the old flasher did not use all the connections anyway, and the price was $21, I passed. Instead, I bought a generic two-prong flasher for three bucks and went home to try it out. Some minor adjustments to the wiring were made (non-destructive, of course), and the new flasher was right at home, allowing me to store the old one. The one flasher operates the turn signals and the emergency flashers. Just as a note, the flasher makes and breaks the connection to do the flashing, that is all. WHAT gets flashed is determined by the signal stalk on the steering column or the emergency flasher. The new flasher has worked flawlessly.

Here’s a brief step-by-step if you need to do the same thing. Procedure is quick and 100% reversible.

Needed:
Phillips screwdriver
Electrical tape
Electrical “Y” connector, one female to double male
Utility clip that will fit the flasher, these are usually made for brooms and tools
Generic two prong turn signal flasher

Steps:
1. Open the trunk and move the trunk liner so you have access to the flasher and wiring. The flasher is usually screwed to the upright support on the driver’s side of the trunk (US version).
2. Unscrew the flasher.
3. Disconnect the brown ground wire and tape over the terminal it to prevent shorting. You will not need this connection for the new flasher.
4. Pull off the white wire from the old flasher and connect it to the input of the new flasher (usually marked with an x). It will probably work on either terminal though.
5. Pull the blue wire and the blue/green striped wire off the old flasher, and connect them both to the “Y” connector.
6. Plug the “Y” connector into the other terminal on the new flasher. Take care that the connector does not short against the connector for the white wire.
7. Inside the car, test the emergency flasher and turn signals to make sure everything is working properly. If it does not, then reverse the connections of the flasher. If it still does not work, you may have a defective flasher or another problem elsewhere in your electrical system.
8. If everything is good, then screw the hardware clip to the same spot the old flasher was mounted.
9. Clip the new flasher in place and you are done.

Here’s the old flasher

The guts!

New flasher wired. Note the ground wire terminal taped over with red electrical tape. No, I did not put that tape there! Overspray is from a PO.

Here’s the hardware clip I used. It was not even in the store computer system, so they gave it to me for 75 cents.

New clip in position

New flasher in new clip, but 100% reversible!

Paul

[glutamodo]

The problem I've always had with US-spec XL flasher relays is that they light up on the dashboard first before they flash to the lights. In 1971/2 VW switched from that 4-terminal relay to a grounded three-terminal setup. These have terminals 49, 49a and 31. And they then used that setup until the late 1990s on all models - so you can see that this was a proven design. The only modification you need to make when changing is that you have to "piggyback" the wire that used to go to kBl over to 49a. And you're done. And - the lights flash OUTside the car first!

-Andy

[Altema]

[Tomskg]

Look here for an alternative setup which uses two relays. More expensive, but it replicates the functionality of the original, which flashes the speedo light in sync with the outside lights. This is how I replaced my faulty flasher relay and I found that two relays click twice as loud - useful when the self cancelling doesn't work.

[glutamodo]

[ovghiaguy]

I used the flasher (4 prong) from KGPR. $13. plus you get tech support

[Altema]

[Altema]

[Tomskg]

[Tomskg]

[Altema]

[azsuns]

I have a 70 Ghia and have installed a new harness in the car before I started my the paint and body work.

So while the car was apart I didnt make all the switch connections. I hooked up the battery yesterday and most of the lights worked, the car started. the int light worked for the first time. Im not very good at wiring and followed the harness instructions. I installed a new turn signal switch on the column because the old wires were splice and cobbled up under the dash.

So my wiring diagram shows a black green and white wire coming off the turn switch and going to the relay and connecting to the dash arrow with the blue and green wire. I dont have a black green and white wire coming from the signal switch? Extra wires are red & black, grey, and blue & black? when I put the signal switch on left or right, the bulbs light in the rear but dont blink. And once the front right lit but dosnt now.

Are any of the remaining wires to replace the blck grn & white wire? I have none from the column going to the flasher. I looked on ebay this morning because they have good pics of a turn switch and didnt see the mystery wire either? Any help will be appreciated. Pictures also.

[kiwighia68]