Long story short, the red wire providing power to the headlight switch will sometimes have power on it, sometimes it wont. I started noticing that the volt gauge would fluctuate a lot with the lights on. Finally one morning they went completely out. Luckily I was close to the house and made it back. No interior lights, no gauge lights, no headlights. Turn signals still work so I knew it was in the headlight circuit.

Couple days pass, I walk out to the car, open the door and the interior lights come on. I pull the headlight switch, the headlights come on. I hit the high beams and they all went out. I assumed it could be the switch,so I pull the dash apart and check the red wire going to it. At that time, it has 12 volts on it and interior lights are back on. I put a new switch in it and suddenly nothing again. No power on the red wire.

Looking at the wire diagram, I assume that red wire goes straight through the bulkhead connector and to the starter? Can the fusible link be acting like this? Or is there an actual circuit breaker in the circuit that Im not aware of?

 

A fusible link can do what is going on. The bulkhead connector can also cause this issue. There is a circuit breaker built into the headlight switch.

RBob.

 

Thanks RBob! That answered everything I needed to know! Guess my first step is to inspect or go ahead and replace the fusible link and go from there.

What in the bulkhead connector can cause it? Corrosion or a lose connection?

 

Finally tore into it yesterday. Harness going from the starter decided at some point to sit on the header and melted. Both fusible links need replacing. One felt like brittle chunks inside.

Thanks for the help again.