83-85 Steering Column Headlight Switch

[davery]

When I bought my 85 twenty-two years ago the headlight switch didn’t work correctly. Turning on the lights was always a hit or miss issue. The lever had the two position up and down, but rotated 360 degrees. About two years ago I removed the column switch and tried to see what the issues was. As it appears the actual switches are inside the column, I was not able to do anything. After re-installing the switch, the headlights only worked on hi beams. I can hear the relay clicking when I go from lo to hi, but the hi beams would not change. I found a used column switch and installed today. Now I have no lights. The new (used) column has the two positions up and down, and three positions by rotation. I have a pdf of the 85 owner’s manual, and this appears to be correct. It says to rotate the switch in the up position to turn the lights on. This does not work. I can rotate the switch, but no lights. When the lo beams are on, the down position is to turn on the hi beams. This does not work either. The funny thing is I can flash the hi beams by pulling the lever toward me, as per the manual. Is my new (used) column bad? Ideas?

[spider2081]

Unfortunately the operation of the steering column switch 83-85 is not intuitive so many are broken by operators.

One common error is the lever is designed so it can not move down to the hi beam position unless first rotated to the headlight Lo beam position. Many have had their levers forced in to the hi-beam position with out first being rotated. This cracks the nylon cam molded on the the lever shaft. Once that happens the shaft rotates but the cam no longer rotates to activate the switches.
The other operating error is the parking lights. The parking lights can operate with the ignition switch in the "off" position (hot all the time circuit) and the steering wheel centered. So rotating the shaft one click from off should turn on the parking lights when the parking light switch on top of the steering column is in its centered position. If the steering wheel is then turned, that will move that switch to either side turning off the parking lights. The switch on top of the steering column only functions when the ignition switch is in the off position.
When the ignition switch is in the "on" position the switch on top of the steering wheel no longer functions. Simply rotating the lever one click from "off" turns on the parking lights. The next click turns on the headlights to the Lo beam position, activation the lo beam relay. Once in the lo beam position moving the lever down activates the hi beam relay and deactivates the lo beam relay.

I have disassembled 6 1983-85 steering column assemblies. Everyone has the nylon cam cracked or broken. Also 2 had the housing for the cam broken. 3 of them had the parking light switch wires cut and spliced leading me to believe previous service attempted to by pass the switch on top of the steering column.

[davery]

Unfortunately the operation of the steering column switch 83-85 is not intuitive so many are broken by operators.

One common error is the lever is designed so it can not move down to the hi beam position unless first rotated to the headlight Lo beam position. Many have had their levers forced in to the hi-beam position with out first being rotated. This cracks the nylon cam molded on the the lever shaft. Once that happens the shaft rotates but the cam no longer rotates to activate the switches.

This is what I believed happened to the car by a PO. Up until a couple of years ago I could turn the rotate lever back and forth and turn on the lights. The headlight lever on the new (used) column I have does seem to rotate and stop. Does this mean the cam is engaged?

I have disassembled 6 1983-85 steering column assemblies. Everyone has the nylon cam cracked or broken. Also 2 had the housing for the cam broken. 3 of them had the parking light switch wires cut and spliced leading me to believe previous service attempted to by pass the switch on top of the steering column.

Can the nylon cams be replaced or is there work around? On both of the columns I have the headlight lever comes out and these is no nylon cam, just the spline in the metal shaft. Is that normal?

Something else I thought of. In looking at the wiring diagram, it appears there is a hi and a lo relay. The power comes to the lo relay and then to the hi relay. I assume both relays are activated for the hi beams? If the lo beam relay was bad, I assume the hi beams would not work. As I said, on my original column switch I have hi beams, but no lo beams.

Thanks for the help, any suggestions?

Thanks for the info, any suggestions?

[spider2081]

There are 4 hollow rivets that hold the headlight switch cover on the assembly. I drill the heads off of them to open the switch.

If you can remover the metal lever out of the switch most likely the nylon cam is broken in some way. The cam is molded to the shaft, in otherwords part of the shaft.

[davery]

There are 4 hollow rivets that hold the headlight switch cover on the assembly. I drill the heads off of them to open the switch.

If you can remover the metal lever out of the switch most likely the nylon cam is broken in some way. The cam is molded to the shaft, in otherwords part of the shaft.

That's what I sort of thought about the lever. So if I open the switch cover up, can I do anything to repair the switch?

[spider2081]

So if I open the switch cover up, can I do anything to repair the switch?

I
'm not sure.
I don't know of any glues that will stick well to the nylon type material the can is made of. Also until its open and inspected you don't know how much damage is done. One of the switches I took apart the cam was in 3 pieces.
Most need cam crack glued and the cam either glued or pinned to the shaft.

[davery]

I have the old column back on. As before I have hi beams, but not lo. When I rotate the headlight lever I can hear relay click. According to the manual, rotating this lever should turn on the lo beams. So I assume the lo beam switch is working and the relay is getting power. I assume the next step would be tracking the gray/red wire going from the lo beam relay to the fuse box? Thanks for your input.

[spider2081]

once you have rotated the lever to the position the hi beams are lit and you then move the lever up. It sounds to me like the "stop" that prevents the lever from being pushed down to the "hi" beam position is broken and your lever is in its lower position which is the hi beam position. the upper position of the lever is the "lo" beam position.

[davery]

once you have rotated the lever to the position the hi beams are lit and you then move the lever up. It sounds to me like the "stop" that prevents the lever from being pushed down to the "hi" beam position is broken and your lever is in its lower position which is the hi beam position. the upper position of the lever is the "lo" beam position.

When the lever is in the up position I can rotate it and hear the click of the relay. Since this is how the lo beams are switched on, I assume this click is from the lo beam relay. Which would mean the lo beam switch is sending a signal to the lo beam relay.

I will try you suggestion tonight.

[spider2081]

I can rotate it and hear the click of the relay. Since this is how the lo beams are switched on, I assume this click is from the lo beam relay

That could be a safe assumption if you knew the system was working correctly. Just a thought relays can make a clicking sound both when energizing and and de-energizing.
Also if someone has miss wired something in the car you could be hearing the hi beam relay energize.

I would drop the relay panel and check the relays wire colors to be sure that is happening.

[davery]

I can rotate it and hear the click of the relay. Since this is how the lo beams are switched on, I assume this click is from the lo beam relay

That could be a safe assumption if you knew the system was working correctly. Just a thought relays can make a clicking sound both when energizing and and de-energizing.
Also if someone has miss wired something in the car you could be hearing the hi beam relay energize.

I would drop the relay panel and check the relays wire colors to be sure that is happening.

I was able to switch the lo and hi beam relays and now everything is working. I have no idea why. Maybe a relay was loose? The only thing now is the turn signals are not automatically going off after a turn. It's always something.

[spider2081]

First be sure your horn ring is properly seated. If you are sure it is then remove the horn ring. Then the 4 screws holding the turn signal switch cover in place. Carefully remove the cover and take a peak inside. There are 2 springs and a few other parts in there. Tedious to assemble.

I have some of the parts for the turn signal switch if you need them. With two switch assemblies it unlikely the same part is bad in both assemblies.