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Thread: Headlight switch burned out!

  1. #1
    Join Date
    Sep 2008
    Location
    Fitzroy, Melbourne
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    127

    Headlight switch burned out!

    Hey all, after fixing a water leak yesterday I replaced the dashboard only to find smoke pouring from it as soon as I started the car (with headlights on). After disconnecting the battery and hunting I found the culprit.. the headlight switch was smoking heavily (intermittently) and had fused itself in the on position. The area that was smoking is the coil behind the dash brightness adjustment wheel (see pic).

    Has anyone experienced anything like this before? I'm wondering if I might have crossed some wires or a loose wire may have touched the coil (although I couldn't see anything like that).

    P.S - Needless to say I need a new headlight switch if someone has one!
    Attached Thumbnails Attached Thumbnails Headlight switch burned out!-headlight-switch-bmp  

    76' 2dr Kjet

  2. #2
    Join Date
    Apr 2006
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    Hobart,Tas
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    I burnt out a switch in my golf years ago at 2am in a rally. I was using 100/80 watt headlight globes without a relay at the time. It burnt the reostat out for the dashlights which in turn stopped the headlights from working.
    I have new switches here for $35 if you need but I am sure you could get a secondhand one over there cheaper.
    Andrew
    Par 6 Golf GTI. Coilovers, BBS CH Wheels, APR'd
    Caddy van 05/07 (colourcoded) (BRIGHT! orange!) coilovers, Konis 18in. wheels, Oettinger tuned

  3. #3
    Join Date
    Feb 2007
    Location
    Melbourne
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    You should relay your head lights. One of the reasons why people relay their headlights it to avoid what happend to you. 25yr old wires dont handle the current well, espcialy if you have higher wattage bulbs in.

    http://www.vintagewatercooleds.com/t.../Headlight.htm

    This happend to me when i was puting LED lights in my mk2 switch, it happend to me for a different reason though, i soldered incorectly.
    MK1 GLS 3door
    A4 B7 2.0T

  4. #4
    Join Date
    Jun 2005
    Location
    Boronia VIC
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    I'd check that the globe holders for the cigarette lighter and ashtray haven't fallen out somewhere and shorted out the dash light circuit.

    Pete

  5. #5
    Join Date
    Sep 2008
    Location
    Fitzroy, Melbourne
    Posts
    127
    Thread Starter
    Thanks for the info guys! Looks like its back in the workshop this Saturday for some TLC (good chance to tidy up the electrics

    I'm thinking of fitting a kill switch, does anyone know the wire which goes from the key ignition back to the starter motor? I've identified the main power wire (the big red one!) with the multi-meter, but want the kill switch to just knock out the engine turning over not the dash electrics etc.

    Cheers

    76' 2dr Kjet

  6. #6
    Join Date
    Apr 2006
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    Hobart,Tas
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    If you still have points type ignition, run a wire from the negative side of the coil to a switch under the dash and to earth, that way it will wind over but wont get spark.
    I used to hook it up to the cigarette lighter and disconnect the power wire that normally goes to it. So, when parked I would just push in the lighter, no spark!!!
    Andrew
    Par 6 Golf GTI. Coilovers, BBS CH Wheels, APR'd
    Caddy van 05/07 (colourcoded) (BRIGHT! orange!) coilovers, Konis 18in. wheels, Oettinger tuned

  7. #7
    Join Date
    Sep 2008
    Location
    Fitzroy, Melbourne
    Posts
    127
    Thread Starter
    The cigarette lighter! Genius!
    I've got electronic ignition, will it still work?
    P.S - anyone got any cheap headlights switches?
    Thinking of buying off ebay but not sure of quality
    http://cgi.ebay.com.au/VW-Mk1-A1-Jet...3A1|240%3A1318

    76' 2dr Kjet

  8. #8
    Join Date
    Dec 2007
    Location
    Somewhere in Melbourne, Victoria
    Posts
    206
    Users Country Flag

    That switch looks like a later model (Mk2 or Mk1 cabrio late 80's early 90's). I have one here in good nick but white lamp icon faded but still in one piece. PM me with an offer.

    Part number is 171 941 531 E and coil (dashboard light dimmer dial is clean with no burn marks.

    DSC01675.jpg

    DSC01677.jpg
    Last edited by paulie71; 11-03-2009 at 08:07 PM. Reason: added pics
    1991 Golf GTI Manual - Tornado Red (Little Red Wagen)
    1998 Golf Cabriolet Manual - Black Magic Pearl (aka Rommel's Panzer) Deceased/written off
    1993 Golf Cabriolet Manual - Alpine White (aka Hitler Youth Wagen) Deceased/written off
    1976 Golf LS Manual - Bronco Brown (aka Roadrunner) Deceased/worn out

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