No power after changing headlight switch on 66 Fury lll

[dcjoe22]

So all my lights were working except the headlights. I changed the bright light dimmer switch on the floor with no change. I bought a new headlight switch and before I put it back in, I wanted to try it. So I turned it on and put the cable back on the battery. As soon as I did that, there was a big spark and a lot of smoke near the firewall. I immediately pulled the battery cable to access the damage. I now have no power when I turn the key on and of course nothing works. I tested from battery to solenoid and tested positive to there and to starter. Thought??

 

[Big_John]

Probably burnt the fusible link up.

You'll have to replace it (easy enough) but before you do, you want to figure out where the short is.

 

[dcjoe22]

Thanks John. Assuming replacing the fusible link wire from starter relay to connector?

 

[Big_John]

Thanks John. Assuming replacing the fusible link wire from starter relay to connector?

Yes, I believe that is probably the one you want to look at first.

 

[CBODY67]

Might end up taking the bulkhead connector apart and cleaning/resealing the contact terminals in it? Find that short-to-ground that let the smoke out.

CBODY67

 

[HOT FURY]

Probably your main power wire or headlight lead going into the bulkhead connector shorted it sounds like, lucky it didnt start a fire. I would replace the bulkhead connector, check all wiring going into it on both sides of the firewall, repair, replace and clean any of the terminals and liberally use dielectric grease. I would do the ammeter bypass while already doing electrical there if you havent already. Why it suddenly decided to short then if it was working before is a mystery. I also replaced my headlight harness on mine with an aftermarket relay kit after noticing my power lead going into my headlight switch was heating up and melted the plug.

 

[dcjoe22]

Thanks for your advice I really appreciate it. Looks like a tough one to fix this problem!

 

[HOT FURY]

not too bad but can be a bit time consuming depending on what it ends up being, I ended up rewiring my whole car after finding a few scary shorts in my headlight switch and bulkhead connector that caused the plastic around the terminal to melt

 

[commando1]

Was the new switch the exact same design as the old one? Auto parts store switches don't work in your car.

 

[Mudeblue]

So all my lights were working except the headlights. I changed the bright light dimmer switch on the floor with no change. I bought a new headlight switch and before I put it back in, I wanted to try it. So I turned it on and put the cable back on the battery. As soon as I did that, there was a big spark and a lot of smoke near the firewall. I immediately pulled the battery cable to access the damage. I now have no power when I turn the key on and of course nothing works. I tested from battery to solenoid and tested positive to there and to starter. Thought??

Could be the starter relay on your firewall. Had the same problem on my 65.

 

[commando1]

bought a new headlight switch

For my own reference, where did you buy it. I have my thoughts on this matter.

 

[Mudeblue]

For my own reference, where did you buy it. I have my thoughts on this matter.

NAPA, Auto Zone or O'Reilley's. Can't remember. I know Classic Industries has and would suspect Summit and rest have. Classics has on page 521 of their catalog, $11.99. Not difficult to find.

 

[dcjoe22]

Hi Guys and thanks for all your advice! I found my problem in that the Male contact on the bulkhead connector that the fusible link went to was cracked. I replaced it and headlights now work!! Can't tell you enough how relieved I was! Thanks again!!!