Hi, Asad, The melted wire sounds like either a poor connection at the relay, or the relay itself is overheating. A bad connection can overheat easily. IF any push-on terminal wiggles easily on its blade, it's lost its clamping pressure and will just get worse with time.
All the problems I have ever had with headlights going out have been with the fuse box. On my '67, there was a water leak around the hood, and the cover of the fuse box would fill with water every time it rained. The fuses all got corroded. I polished the fuse contacts with emery cloth and put a coating of petroleum jelly on them - no problems for quite a while now. Chuck Kuecker asad ishaque wrote: > Hello all, > > My daily driven 68 has a prob. The headlights are troublesome. > They have a history of 'acting up' with one of the beams not > funtioning followed by both beams not working. This was cured by > cleaning the terminals at the fusebox and the headlight relay n > switch. Relay was put brand new few years back and is a brazil VW > item. Headlight switch, genuine VW. > > Currently first the high beam stopped working. On flipping the > indicator lever, the relay clicked and switches the beam (to darkness > if high). Couple of days later the low beam also stopped working. Now > none of the beams work but I do have a brief flash when I pull the > indicator lever.....if I keep it pulled theres light. > > I had long noticed a slight smell of something frying in the car. > On examination I found the wire going from the switch to the relay had > its clip plastic insulator molten in place on the relay side. > > What should be done here??? Do you guys suppose its a bad Headlight > switch or theres a problem in the relay?? Alternatively can it be just > bad wires and crappy connections? > > I can replace the relay and the headlight switch but I dont want to > miss on something which can be eliminated. > > TIA > > Asad > Karachi, Pakistan. > _______________________________________________ vintagvw site list [email protected] http://lists.sjsu.edu/mailman/listinfo/vintagvw
