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Overheated / smoke from high beam switch

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Old Sep 10th, 2005, 20:06   #1
VinVolvo
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Default Overheated / smoke from high beam switch

I've attempted to trace an electrical short that is causing the horns to not function. Tracing the wires from the horn I found what is likely a hot connection. There is a fault in the continuity from the left side high beam. None of the fuses has as yet to trip.

Firstly, the connections from all ground points are clean. The wires to the horns are clean and tested. The left high beam harness (3 contacts) demonstrates continuity to the ground contacts from each contact. That's from either of two ground points, one on the chassis, the other being the ground wire connectors to the horn.

When the LH (high beam) fuse is pulled, the center pole on the LH harness is null to either of the two ground points. The RH beam connector test properly. (Only the leads are not long enough to reach across and test to the horns harness, but only to the ground point attachment on the chassis by the battery.)

When the horn switch is depressed indications are that the switching is working properly. However, the (tested) horns fail to function?

The ground wire from the wiper control switch is good at the steering column. However, when the high beam switch is held to the on/open position manually, it then begins to overheat causing smoke.

Cross checking from the pulled fuse entries of the horn’s fuse and the LH fuse, again the continuity signals momentarily, when changing position. At this point I’m not clear as to how to interpret results. I’m holding the leads from the ohmmeter to each of the post on the fuse and checking to see if I can detect the short on the headlight’s fuse or the horn’s? I know the wire that is shorted is the center contact post wire on the left headlights harness. I don’t know why if it is a faulty headlight relay, that it could cause the horn not to work. I do know that the bulb failure light does not appear to function...

Is this likely a fault in the headlight relay? Or rather is this likely the turn signal headlight switch malfunctioning?

93' V940 wagon

Thank you,
Vin
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