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Bad Headlight switch blowing fuses

Discussion in 'Early CJ5 and CJ6 Tech' started by Smokeater, May 7, 2011.

  1. May 7, 2011
    Smokeater

    Smokeater Sponsor

    Browns Summit, NC
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    Jun 1, 2009
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    Well, since the CJ has became the temp. DD I've only had 1 problem. About 3 or 4 times a week my headlight switch would blow it's fuse, but only when the switch was pulled and never when going down the road. After several hours of troubleshooting I narrowed it down to the HL switch, so I ordered a new one. Well, put the new one in and still the same prob.:mad:. After more troubleshooting, this is what I found
    [​IMG]
    [​IMG]
    When the switch was moved from parking to headlights the bracket inside the switch that the bottom arrow is on was tilting up & hitting the back contact, shorting the switch out. My fix was to just take the dremel to that area and no more problems. I'll call the vendor Mon. for the make of the switch (prob OMIX) and post it up. HTH someone down the road.
     
    Last edited: May 7, 2011
  2. May 7, 2011
    chicklin

    chicklin New Member

    Kansas City, MO
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    Feb 27, 2009
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  3. May 7, 2011
    Smokeater

    Smokeater Sponsor

    Browns Summit, NC
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    I don't wanna out the vendor because it's not their fault.

    Just checked and my part number matched the one in your link. The first switch was in there about a year or so but only driven once a week and not always in the dark. The second switch blew the fuse on the first pull.
     
  4. May 8, 2011
    1960willyscj5

    1960willyscj5 Well-Known Member

    Mesa, Arizona
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    Nov 27, 2006
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    I would be inclined to think there is a wire rubbing some place that is causing this.
     
  5. May 8, 2011
    chicklin

    chicklin New Member

    Kansas City, MO
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    Does the switch otherwise function normally? If so, I would agree. Mine was blowing fuses, but the switch was going bad b/c you had to wiggle it a little to get the taillights to come on. I figured it was screwed up internally.
     
  6. May 8, 2011
    1960willyscj5

    1960willyscj5 Well-Known Member

    Mesa, Arizona
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    I replaced mine with one from AutoZone. Can't see any difference, really. Works just fine.

    I think you need to trace out your wiring though and see if you have something shorting out some where.

    All that wiring is 40 years old, unless you re-wired the whole thing at some point.
     
  7. May 8, 2011
    Smokeater

    Smokeater Sponsor

    Browns Summit, NC
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    Jun 1, 2009
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    Nope, It would blow the fuse with only the power hooked to the switch, but would not blow with the switch out of the dash! If you look at the sorry pics, at the tip of the knife you can see the small weld mark where the contact was made. That weld mark showed up on both switches. After the dremel tool fix I have had NO problems. Trust me, I checked all the wiring more than once!
     
  8. Aug 11, 2012
    robbetaylor

    robbetaylor New Member

    Stockton, MO
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    Jan 12, 2012
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    I was wiring up the cj5 after my restoration today and had the same problem with a new switch. It would work perfect for 3 or 4 pulls and then pop the fuse. I figured it was in the switch because it only shorted while I was pulling the switch out. Once the lights came on they worked fine for as long as you wanted to leave them on. I came in and searched the forum and found this thread. Smokeater was right on with this one. I took the switch apart and there it was, the small weld burn on the slide where it had been hitting the hot post and shorting out. Took the dremel to it and it works like a new one, ( oh yeah, it is a new one ). Great forum again!!! Hours and money saved again.
     
  9. Aug 12, 2012
    1960willyscj5

    1960willyscj5 Well-Known Member

    Mesa, Arizona
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    Remember, 'New' doesn't necessarily mean 'good'.
     
  10. Aug 12, 2012
    Walt Couch

    Walt Couch sidehill Cordele, Ga. 2024 Sponsor 2023 Sponsor 2022 Sponsor

    cordele, Ga.
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    I noted that all reference to this switch says "blows fuse". The headlight switch should be supplied power through a circuit breaker. It could be they are using wrong terminology but just in case, once again use a circuit breaker or headlight relays.
     
  11. Aug 12, 2012
    robbetaylor

    robbetaylor New Member

    Stockton, MO
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    You are correct, the switch has a 30 amp circuit breaker on it, but I went a head and fused it also. Probably not necessary but made me feel better.
     
  12. Aug 12, 2012
    Smokeater

    Smokeater Sponsor

    Browns Summit, NC
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    Well in my my case Walt, I'm using an EZ-WIre harness so it's wired to a fuse. It does have the circuit breaker on the switch though. After thinking about it, do you think it would be a good idea to put in a fuse alittle larger than what the cicuit breaker is rated? That way the cicuit breaker would do it's job.
     
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