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In Reply to: Re: headlight intermittently going off posted by Bob H. on January 28, 2001 at 13:45:38:
To open the long black module, I used four credit cards, one at each corner to override the tabs.
Sounds like the usual solder joint fatigue problem in the light module, which is easy to fix. Remove the module from the fuse box, it's the long slender black box. You can remove the innards (circuit boards) from the housing by prying a couple of tabs on the bottom. Examine the high current solder connections leading from the connectors to the relays on the board, and look for cracks in the solder. Take a small soldering iron suitable for electronics work, and re-melt the joints and add a little fluxed solder (be sure to use electronic solder with none acid flux). You can get both the iron and solder at Radio Shack. In my case,at 200K miles, I also had intermittent failure on the right low beam, and found a definite solder defect upon initial inspection. Check you other relays too, at least the ones that are dismantleable, one in particular that gives problems is the light fault detecting circuit relay (it tells you your tail and parking lights are defective when they really aren't). What happens is that the relatively high currents passing through either of the devices heat up the solder joint, and repeated heating and cooling leads to fatigue and cracking of the joint, and it has to be re-melted for repair. Bob H.
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