66 67 headlight operation?

[Rolling_Thunder]

so i have a customer coming in for non-operation headlight doors on a 1966 dodge charger...     what should i start looking at first?

[A383Wing]

A service manual would be the first place to start. Don't go poking around in the hidden headlight system without one.

Bryan

[Ghoste]

It's a fairly complicated setup and the most usual problems are with the realays but after this many years, it could be anything.  The first thing I would do is to determine if it's the motors (which can "gunk" up) or the operating system.  Unhooking the motors from the harness and applying a little 12 volt to them can help with that.  There is a ground, open, and close in the connector so you'll have to make sure you wire them right to test.  Next, you can make sure the limit switches are all working good.  Simple multimeter stuff there.  Check that the nubs on the end of the contact arms haven't worn away and thus not allowing the imit switch to close all the way.  You should also make sure all the connections are good.  The headlight switch is working good (not just turning the lights on but allowing the current to flow through for triggering the motors to come on.  Make sure the headlight open switch isn't sticking.  This is a separate switch that allows the option of opening the headlight buckets and then shutting off the lights but having the buckets remain open.
There are a large number of things to check and as Bryan said, an fsm is indispensable for working on it.  You will need to follow the diagnostic procedures in there and you will need the wiring diagrams.

[Rolling_Thunder]

thanks guys...    i'll let you know what i find   

[3--Daytona]

In the area of 66 & 67 headlites,,,this man is the gureu;;;;;;

                Jim Rodebaugh
                394660 Gap Road
                 Ochelata, OK.  74051
                918-333-5573

                                                 3--daytona

[Rolling_Thunder]

Well I figured it all out...   

1) I connected the motors to 12V directly (bypassing relays and wiring) and one operated poorly, the other not at all...    so i disassembled both motors and fixed, cleaned, restored them

2) Relays were fused and not operating, so i again disassembled, fixed, repaired them

3) poor contacts on multiple connectors led to insane drop in current and heat build up - connections were all replaced


System now works...     

Makes me feel good that I did not have to farm any of this stuff out...     

[Charger-Bodie]

Well I figured it all out...   

1) I connected the motors to 12V directly (bypassing relays and wiring) and one operated poorly, the other not at all...    so i disassembled both motors and fixed, cleaned, restored them

2) Relays were fused and not operating, so i again disassembled, fixed, repaired them

3) poor contacts on multiple connectors led to insane drop in current and heat build up - connections were all replaced


System now works...     

Makes me feel good that I did not have to farm any of this stuff out...     

great job!!

[Ghoste]

You have passed the first step of acceptance into the fastback cult.  Next you have to repair guages and el lighting and you will nearly be ready to be allowed to buy one. 

[Rolling_Thunder]

You have passed the first step of acceptance into the fastback cult.  Next you have to repair guages and el lighting and you will nearly be ready to be allowed to buy one. 

I got my ASE cert in Auto electrical...     BRING IT ON!   

[Musicman]

Good job... sounds like you had to go through quite a bit to get it done, but you got it done... 

See, it wasn't non-operational "Headlight Doors" afterall was it    Welcome to 1st Gen. headlamp systems.

Mike (What doors? I don't see any doors.)

[Ghoste]

You have passed the first step of acceptance into the fastback cult.  Next you have to repair guages and el lighting and you will nearly be ready to be allowed to buy one. 

I got my ASE cert in Auto electrical...     BRING IT ON!   

And here I was getting all set to post the fsm diagnostic procedures and wiring diagrams.

[Rolling_Thunder]

You have passed the first step of acceptance into the fastback cult.  Next you have to repair guages and el lighting and you will nearly be ready to be allowed to buy one. 

I got my ASE cert in Auto electrical...     BRING IT ON!   

And here I was getting all set to post the fsm diagnostic procedures and wiring diagrams.

Would you mind posting them anyway just so I can have a copy for the shop ?

[Ghoste]

Not at all.  I'll need some time to shrink them down but here are a couple for now.

[Ghoste]

First page.

[Rolling_Thunder]

do you also have the service bullitens for the headlight system ?


So - one more question - where do i source new relays ?   or has anyone ever converted to conventional Bosch relays ?

[Musicman]

I'll need some time to shrink them down but here are a couple for now.

Ghoste

You'd be better off emailing the stuff to him full size... by the time you get done compressing everything, making it small enough to post, there won't be much left to read.

Mike

[Ghoste]

I think you're very correct.  That or maybe a photobucket link.

[Rolling_Thunder]

if you would like to e-mail me - you can at       Acampadonia@Iconengineeringinc.com

[Ghoste]

I'll have to look.  I have a stack of old bulletins and that one may be in there.  The info won't be much different in any case from what I am going to send you.  As to relays, at one time Keisler was repopping them but I don't know if he does that anymore or not.  The best option to find relays would be to follow the link in my sig to the 66-67 website.  Once there, you need to look up David Walker.  He is a mod on the site so he's easy to find but in addition to being a mod (and a helluva good guy to boot), he is also one the fastback cults high priests.  He has been tasked as the keeper of knowledge and what I am about to tell you is one of the seven essential secrets to the fastback cult and I could get in a lot of trouble for revealing it to someone who doesn't own a 66 or 67 but I'm going to trust you.  You must approach David Walker and offer only these words, "show me thusly to the source guide".  When you type in "source guide", you must humbly avert your eyes.  If the keeper of knowledge (did I mention what a great guy he is?) deems you worthy, he'll show you a path of enlightenment and reveal one of the sacred fastback texts and in there, you may discover relay options.
In other words, I have no idea but that guy might.

[Musicman]

So - one more question - where do i source new relays ?   or has anyone ever converted to conventional Bosch relays ?

Ghoste is correct, you should check in over at the 66-67 site for the info. your looking for. I can tell you that the answer to your question about Bosch Relays is "YES"... many of the guys over there are using the Bosch relays... as a matter of fact, one fella recently created a new headlamp modification which doesn't allow the lamps to light until the lamp buckets are fully open, using Bosch relays. Kinda cool actually...