Headlights Wont Work

[04offroader]

So we have a 93 festiva with a B6 swap and stock wiring. The headlights will not come on. When we make the connection the relay will click, as well as the high beam relay. The power is not making it to the fixtures somehow. The bulbs are brand new, and we cleaned the contacts on the fuse box mounted to the shock tower. If anyone else has had this trouble please let me know how you solved it. This is a frustrating problem to have when all of the wiring is un-tampered with. We have the running/parking lights plugged in as well and even they are not getting power. Thank you to anyone who posted on my urgent thread, its seems to have been deleted for some reason. We wound up wiring a cheap set of bajas for the rallyX.

[Micro Mudder]

I had this happen before while driving at night went to turn my dims on and lost all power to lights on a turn 30 miles from home haha. I cleaned the fuses on the shocktower but didn't work so I replaced the wires on the fuse box on the shock tower and it worked so try replacing the wires is my only thought

[Pu241]

Actually, you double posted and I merge the posts into a single thread and then for some reason deleted the wrong thread.
Sorry, its back now.
Will likely merge any other posts into that as well.
Do you know if the fusible wire itself is good?
Did you get long legged cartridge fuses to replace the wires?

[04offroader]

No we didnt replace them we just cleaned the contacts. The problem is if these were blow wouldnt the relays not click?

[Pu241]

Relay "clicks" because the switch is turned to "on" position and relay engages.
If the connection on the relay side is good or bad it will still "click" as it is an electro mechanical device.
I'm now betting on simple burned out/corroded fusible link.
Let us know.

[04offroader]

Relay "clicks" because the switch is turned to "on" position and relay engages.
If the connection on the relay side is good or bad it will still "click" as it is an electro mechanical device.
I'm now betting on simple burned out/corroded fusible link.
Let us know.

Yes I understand this, but if the fusible wire was bad, then the electricity would not reach the relays because of a broken circuit. Unless ford ran the power to the relays first, then back to the fuses, and then to the fixtures. This might be true because I haven't had time to look over the wiring diagram. We did swap the two fusible wires of the same amperage to no avail. I guess a simple solution would be to bypass that little box with some inline fuses.

[bravekozak]

offroad is correct. Power splits from the head fusible link to both red wires on the headlamp relay.
Check to see if power leaves the headlamp relay through the white wire.

If so, then check to see if power gets to the headlamp switch through the white wire.

If so, check to see if power leaves the headlamp switch through the red/blue wire (low beam).

If so, then check if power arrives at the headlamps through the red/blue wire.

Just use a test light with a long point on it. Good luck.



Parking lights go through the tail fuse. If your instrument cluster lights work, your tail fuse is O.K.

If I were a betting guy, I would suspect the headlamp switch (only if all the connectors are plugged in properly in the right places)

[Flw Sock]

If the sound is what I think it is, I might have had the same problem.

I found the "bad" wires in the fusible link box, and just covered the entire holes they were in with solder. The contacts were dirty and I had cleaned them, but they still did not work when I did it. I haven't had a problem since I soldered them in.

[bravekozak]

I took mine out and Dremelled them. Brass spades can be cleaned up as good as new.

[04offroader]

I am going to bypass the fuse box at some point in the next two days, it cant be the switch unfortunatly because the stalks have been removed (they get in the way during rally sessions). Thanks for the ideas