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!Serious Electrical Problem - Headlights quit working without warning 850 1996

Hello All,

I have a 1996 850 GLT wagon with 330,000 miles on the odometer.. Tonight, I went to put my headlights on. As I switch from the "O" (Off) to the parking lights setting, the parking lights came on. Then as I switched to the "On" portion for the headlights, the headlights did not come on and all the lights, including the parking lights and dashboard lights went out. Suddenly, the "ABS" and "TRACS" light came on. I had the ABS unit previously repaired by Victor Rocha. I flip the headlight switch several times and the head lights still did not come on. Suddenly, the headlights came on (along with the dashboard lights) and the "ABS" and "TRACS" light went off.

I turned off the car, turned it on, and once again the headlights would not come on (instead all the lights went off) and the "ABS" and "TRACS" came on. I had a spare light switch, so I installed it and still the lighting problem continued: yes, I had parking lights, but once I turned the switch to turn on the headlights, all lights went off including the dashboard lights and the "ABS" and "TRACS" came on.

I re-installed the original light switch and suddenly everything worked correctly and the "ABS" and "TRACS" went off. I have no idea what is causing this intermittent problem. However, next week I am driving down and back from VA and I cannot afford to lose my headlights. Has anyone else experienced problem? Does anyone have any ideas what could be causing it? Thanks to all who respond.

Hugh








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Hello All,

I want to collectively express my thanks to all who responded. Your suggestions were very helpful. In the end, the cause for my electrical problem described above was due to a worn ignition switch. I have never replaced it and my car is 23 years old and has 330,000 miles, so I can't really complain. However I want to again thank everyone who replied.

Hugh



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It could also be the dimmer switch.
--
Keeping it running is better than buying new



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Klaus,

Thanks to you response and Jim's and Bill's above, I have some possible solutions to share with my private mechanic. As I mentioned above, I am driving down to VA on Wednesday. I know I will be driving in the dark going down and in coming back and I hope to avoid the nightmare of driving without lights. Thank you for sharing your advice.

Hugh



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Cycle the light switch back and forth several times - does it feel funny? Can you push the knob in a bit?

Remove your headlight switch and look at its case.

There are small tabs that hold the case to the body of the switch, the case breaks here.

A temporary repair can be made with electrical tape, prehaps a permanent one with epoxy.

To remove the switch, gently try to pry it out with a small screwdriver. it has been years since I repaired the switch in our '95 855 base, so I do not remember which side to pry.

One side of the switch has a claw type holder, the other side a detent. If you pry on the wrong side, you will break the claw. Pry gently on one side, if that does not work, try the other side.

Many small parts, like lamps and switches use this arrangement.



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Jim,

Thank you for your reply and suggestion. This problem concerns me, because I am about to drive down to VA on Wednesday to pick up my daughter from college and will be driving back in the dark.

Hugh



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The light switch, and the headlight relay, plus loose ground wires are the top
suspects. The ground in question is near the battery box. The relay is the
large rectangular module marked 104/105 in the main fuse box.

Bill



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Bill,

Thank you for your reply and suggestion. I will follow up with my mechanic.

Hugh



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