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Unread 09-29-2013, 10:59 AM   #31
MoneypitCJ5
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1977 CJ5 
 
Join Date: Mar 2013
Location: Florence, AL
Posts: 170
Well after spending yesterday working on it, here's what all I found:

1) I had to rebuild a harness for the front lights, splicing my original firewall connector to a 84 CJ7 harness (thanks to previous owner) and incorrectly wired the left and right turn signal. Both wires at the plug were green instead of green and green with tracer.

2) A cold factory splice for the passenger side turn signal wire

3) Poor grounds everywhere!

After doing all this, my brake lights literally worked fine for about 5 minutes and then suddenly stopped. Turn signals, parking lights and headlights work fine. I ran out of daylight but I'll try to run down the brake circuit tomorrow or Monday and get back to you.

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1973 VW Karmann-Ghia first car
2009 Challenger R/T 6MT, Flowmaster, inTune daily driver
1977 CJ5 304, 3MT - under construction
And many in between!
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Unread 09-29-2013, 04:56 PM   #32
bligon64
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1974 CJ5 
 
Join Date: Jul 2012
Location: Kennesaw, GA
Posts: 131
Grounds grounds grounds, always seems to be the problem LOL
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Unread 10-02-2013, 11:48 PM   #33
CourtneyUGA
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1985 CJ7 
 
Join Date: Sep 2013
Location: Doyline, Louisiana
Posts: 19
Check your fuse if you say it blew after five. If its blown, try putting a new one in. If it blows, you def know you have a ground lol. and in that case, throw a staple in it until you find the ground so you at least have brake lights.
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Unread 10-02-2013, 11:53 PM   #34
MoneypitCJ5
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1977 CJ5 
 
Join Date: Mar 2013
Location: Florence, AL
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What I found I can only explain as bad connections. After poking around on the brake light switch plug, they started working.....

Of course, those same bad connections also cause weird voltage drops across the system. There's not enough juice even with the engine running for the turn signals to work with the headlights on :/

It looks like I'll be rebuilding my wiring harness over the winter. No biggie, I needed a winter project anyway!
__________________
1973 VW Karmann-Ghia first car
2009 Challenger R/T 6MT, Flowmaster, inTune daily driver
1977 CJ5 304, 3MT - under construction
And many in between!
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Unread 10-03-2013, 11:17 AM   #35
LumpyGrits
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1985 CJ7 
 
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Location: The Mojave Desert Palmdale Ca. U.S.A.
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Quote:
Originally Posted by CourtneyUGA View Post
Check your fuse if you say it blew after five. If its blown, try putting a new one in. If it blows, you def know you have a ground lol. and in that case, throw a staple in it until you find the ground so you at least have brake lights.
That staple is a real good way to start fire.......
LG
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Unread 10-03-2013, 11:24 AM   #36
MoneypitCJ5
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1977 CJ5 
 
Join Date: Mar 2013
Location: Florence, AL
Posts: 170
If nothing else, it's a good excuse to upgrade things!

I'll update it to an ATO fuse block and headlight relays for starters...any other suggestions while
I'm in there, LG?

I have found a harness kit for a Chevelle that uses the right fuse block and comes with the wire for about $150. Would that, in combination with new Packard 56/59 terminals, be a good way to start?
__________________
1973 VW Karmann-Ghia first car
2009 Challenger R/T 6MT, Flowmaster, inTune daily driver
1977 CJ5 304, 3MT - under construction
And many in between!
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Unread 10-03-2013, 11:37 AM   #37
LumpyGrits
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1985 CJ7 
 
Join Date: Jul 2010
Location: The Mojave Desert Palmdale Ca. U.S.A.
Posts: 5,181
Check for frayed wiring where the harness goes over the steering column brace behind the dash.
This sheet metal brace has many sharp edges and will wear/cut the insulation creating a direct to ground 'short'.
Both my '85 and my sons '79 had this issue.
The fix is to sleeve the harness with garden hose where it travels over the brace.
LG
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Unread 10-06-2013, 04:10 PM   #38
CourtneyUGA
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1985 CJ7 
 
Join Date: Sep 2013
Location: Doyline, Louisiana
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Haha we have always used staples if fuses keep blowing until we find the ground. one of my family members is an engineer and they do it at his job.
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Unread 10-06-2013, 04:22 PM   #39
LumpyGrits
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1985 CJ7 
 
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Quote:
Originally Posted by CourtneyUGA View Post
Haha we have always used staples if fuses keep blowing until we find the ground. one of my family members is an engineer and they do it at his job.
Hope he lives till retirement........
LG
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Unread 10-12-2013, 08:49 PM   #40
MoneypitCJ5
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1977 CJ5 
 
Join Date: Mar 2013
Location: Florence, AL
Posts: 170
I FINALLY tracked down my problem with intermittent brake lights!

Turns out, the contacts for the brake light fuse had corroded and weren't making a good connection. Problem solved
__________________
1973 VW Karmann-Ghia first car
2009 Challenger R/T 6MT, Flowmaster, inTune daily driver
1977 CJ5 304, 3MT - under construction
And many in between!
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