Having a problem with the dims on my headlights. The Brown wire that supplies power to the dims gets hot when on. From what I can see in the wire diagram the brown goes from the dimmer switch to the fuse box. Does not blow the fuse but gets hot enough that you can't hold on to it. Tried a new dimmer switch but still gets hot. Any ideas what to look for? Car is a 1971 GS.
Check for a short to ground in that wire, from the switch-to-dimmer, then from dimmer-to-headlights. Lots of pinch points and possible hot spots.
In addition to that, check the grounds for the headlight harnesses, the black wires with ring terminal. Check the grounding/bonding of the dimmer switch to the floor pan. Check the ground ring for the headlight switch (looks like a washer with a tab) and is sandwiched between the switch and the dash.
It seems odd that the wire would get that hot and the fuse isn't blowing? Is it a correct fuse? I would think a hard short to ground would be the explanation for this, but then the fuse should blow. Are the lamps normal, or is it possible you put in some kind of bulb that uses more current? Like Halogen?
I thought headlights weren’t fused? Don’t they use a circuit breaker instead? Is it tripping and resetting? Either way, heat equals resistance, check your connections and grounds. Patrick
My high beams with start to flash after they've been on for 15 / 20 mins. Started after I put halogen bulbs in there. Thinking its that small circuit breaker in the fuse panel
Headlight switches have a thermal breaker that trips. Common for halogen to do this. I put relays for my lights using the switch to power the relays. There is a thread on it somewhere. I'll try to find.
One of the fusible links powers the headlights. Is the fusible link still there. I have seen people eliminate them. Not a good idea.
OK, checked everything mentioned and no dice. I have owned this car for 30 plus years so it's not a new buy. Grounding ring in place behind headlight switch, fusible link at starter, all headlight grounds secured, tried a different headlight switch, different dimmer switch, checked for rub through behind fuse block. ???? I hate electrical problems.
How about the headlights themselves? Are they working? Might be worth trying different headlights. Maybe one of them is drawing too much amperage for some reason?
Cheap enough, worth a shot. https://www.rockauto.com/en/catalog...,electrical-bulb+&+socket,headlamp+bulb,11701
Found the problem, the brown wire on the plug going to the dimmer switch was not making good contact, replaced the connector and everything is 100% like it should be. Thanks for all the help and replies.
