Ugh! It never ends... Headlights not working now. - JeepForum.com
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Unread 03-01-2013, 04:38 PM   #1
MyKeyB
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1997 ZJ 
 
Join Date: Feb 2013
Location: Youngstown, Ohio
Posts: 300
Ugh! It never ends... Headlights not working now.

Does anyone have a schematic (KoreaZJ) for the headlight switch in a 97?
I Resoldered the headlight switch and it worked great. Had a problem with the fuse panel getting moisture in it and keeping the heater and VIC on. Got that fixed and now the headlights won't work and fuse #4/airbag blows everytime I turn on the ignition. The headlights came on yesterday for a couple of seconds and then went out. It does not matter if the switch is on auto or manual. Fog lights also do not work. High beams will flash on when the stalk is pulled but will not stay on. The dimmer switch will still turn on the interior lights. Got a short somewhere I think and would like the schematic to help trouble shoot.

Thanks and if anyone has any thoughts on it I would appreciate it!

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Unread 03-01-2013, 05:35 PM   #2
durango-bob
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2000 TJ Wrangler 
 
Join Date: Jul 2008
Location: Sioux Falls, South Dakota
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See here for an on-line manual:
http://www.jeep4x4center.com/knowled...?utm_source=cj
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Unread 03-02-2013, 05:01 AM   #3
KoreaZJ
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1994 ZJ 
 
Join Date: Aug 2011
Location: GANGNAM STYLE
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Headlamps and fogs share a common ground, check inner fender near battery.

Junction Block Fuse#4 (10 amp) only supplies power to Airbag Control Module in center console (DB/WT wire) near parking brake handle. Might have a short in Junction Block. Disconnect battery NEG cable, wait a few minutes, unplug ACM, check if wire is still grounded.
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Unread 03-02-2013, 09:49 AM   #4
MyKeyB
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1997 ZJ 
 
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Thanks! I'll give it a shot.
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Unread 03-02-2013, 07:34 PM   #5
MyKeyB
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1997 ZJ 
 
Join Date: Feb 2013
Location: Youngstown, Ohio
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Decided to pull the dash and harness and repair whatever I find.

Junction box still has water in it.

Oh well, I pulled it and I am in the process of cleaning and drying the plates. If anyone would like I have a few pics of the inside of the junction block as well as the 6 plates.
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Unread 03-03-2013, 01:36 PM   #6
KoreaZJ
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Quote:
Originally Posted by MyKeyB View Post
...If anyone would like I have a few pics of the inside of the junction block as well as the 6 plates.
Please post here to help others.
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Unread 03-03-2013, 04:29 PM   #7
MyKeyB
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1997 ZJ 
 
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Location: Youngstown, Ohio
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Panel


Water


Pins and more water


Plates with pins removed


Plates


Plate 1 (top plate)


Plate 6 (bottom plate)


After taking it apart and seeing the inside I think it would be almost impossible for it to short out.
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Unread 03-03-2013, 07:56 PM   #8
MyKeyB
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I'm not going to lie. I was pretty scared to pull the pins and seperate the plates. My wife took one look at at the junction block "guts" and told me "no way!" If anyone needs to do this, take a lot of pictures so you can put it back together again. It wasn't as bad as I thought it would be. The pictures I took helped. I labled the board and marked all the pins A B or C.
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Unread 03-04-2013, 05:30 AM   #9
KoreaZJ
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Great pics!

Why so many wafer layers? Do they all have different circuits traces on the back?

How does it maintain good electrical contact between the layers?
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Unread 03-04-2013, 08:49 AM   #10
MyKeyB
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1997 ZJ 
 
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Not sure on the layers. Yes, they all have traces on the back.


It does not maintain any contact between the layers. All the traces go to the pins which go through the layers of plates and then get connected to relays and wiring harnesses etc.
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Unread 03-06-2013, 04:02 PM   #11
MyKeyB
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1997 ZJ 
 
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Got the dash pulled, junction box cleaned and dried, and found the leak. It appears that momma mopar missed a small seam when sealing at the factory. Or maybe the original seal failed. Anyway I have a tiny leak at the corner of the passenger side cowl. Pulled the wipers and cowl cover and applied new seam seal. First time ever using that thick nasty stuff. I hope it works. I think it should, find out tomarrow when it drys.
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Unread 03-07-2013, 07:13 PM   #12
MyKeyB
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Seam sealer worked great. No more leak. Yea! Dash back in but lost light before I could finish reinstalling it. Sorry to keep bumping this but hope it can help someone else. Should be the last update unless anyone has questions.
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