Headlight issue

[svslow]

I pulled my 86 out of storage oil changed and gassed it up. Went to use the headlights this evening and noticed they're super dim. After driving a mile they began to turn on and off on their own. weird. Anyone know that it may be?

[MikeFleming]

Two areas that can cause your symptoms:

1) Headlight switch and associated harness connector. Remember to get the 9-connector harness repair so it includes the fog light circuit.

2) Check out the ground wires and attachment to the radiator core. Look just outside the hood bumper stops for a small hex head bolt mounting a wire loop end. One on each side of the radiator core top.

Each of the front lights (corner, turn signal, inner marker and headlight) grounds are crimped together with one small, ~16 gauge wire coming off the wire crimp to that eye loop. Make sure the metal is clean and unpainted and the bolt (hex screw) is tight enough to insure proper electrical contact. Install a star-type lock washer if needed. The poor wiring gets worse after a few years of high-wattage headlight bulbs.

What the wire crimps look like:
826182628264

Factory ground lug with longer wire.
8263

I made a second wire to solder in parallel with the original one using larger gauge wire. 82658266

Wrap/crimp then solder.
82678268

Cover with Liquid Tape (in black).
82698270


Cover with that harness wrap stuff, scrape the paint off and re-attach to the radiator core. Just like they do downtown.

[svslow]

That's awesome. I'm positive this is the issue. Thanks a lot.

[Under Pressure]

Headlight switch. Ford headlight switch in the 80s Bad on all the cars & trucks.