If you are running Halogen headlights or similar, they require more amperage to function which in turn has the tendency of causing overheating. The overheating in turn leads to premature failure of the switch. The 356 guys solved the issue by installing relays in the hi/low beam circuits. You might try that approach Bill Smothers 65C 219655 Charleston, SC ----- Original Message ----- From: "asad ishaque" <[EMAIL PROTECTED]> To: <vintagvw@lists.sjsu.edu> Sent: Friday, August 24, 2007 6:52 AM Subject: Re: [vintagvw] 68 bug Headlight problem
> Volks, > > I had fit a brand new headlight relay earlier for the probs I > described. > Still there was a smell of overheating while driving the bug at night. > > 'Investigation' while driving revealed that the headlight escutcheon > was heating up. > > Took the trouble of some more tinkering today. Found this: > > The wire connectors going from terminal 56 of the headlight switch to > terminal 56b of the relay was heating up. In fact the plastic clips on > both > ends were melting up and turned to globs. > > Rummaged thru my parts bin to find another good headlight switch. > Cleaned it up and installed. (had noticed that there was a slight amount > of > rock in the previous switch's terminal 56). Still heat. Then took a fresh > piece of wire, crimped new clips at both ends and installed. Made sure > clips > were tight n snug. > > Well after this the wire still heats up but not as much as before. > > I may get shot by the people for not revealing this earlier but Im > running higher than stock wattage bulbs for the heads. Could this be the > source of probs??? > > I am now thinking of having another aftermarket non vw relay working > with the original relay for switching on the headlights. Would that make > life easier??? Can people suggest where I should put that assuming its a > good option. > > > Waiting for input. > > TIA > > Asad > Karachi, Pakistan. > >>From: "asad ishaque" <[EMAIL PROTECTED]> >>Reply-To: Air-Cooled Volkswagen Discussion List <vintagvw@lists.sjsu.edu> >>To: vintagvw@lists.sjsu.edu >>Subject: Re: [vintagvw] 68 bug Headlight problem >>Date: Wed, 08 Aug 2007 11:40:19 +0000 >> >>Hello Chuck, >> >> The loose terminals were on the relay, so I guess the probs fixed. >> I >>will however check for any hot spots as described by another member here. >> >> The plastic fuse box cover is missing on all my cars. In fact I >> have >>yet to SEE a cover in person in my years of VW and VW parts hunting. All >>have been thrown out by the owners or the people who are trusted with >>doing >>jobs on VWs. Sad. >> >> Bearing grease may be a better option as you say. >> >>Asad >>Karachi, Pakistan. >> >> >> >From: Chuck Kuecker <[EMAIL PROTECTED]> >> >Reply-To: Air-Cooled Volkswagen Discussion List >> ><vintagvw@lists.sjsu.edu> >> >To: Air-Cooled Volkswagen Discussion List <vintagvw@lists.sjsu.edu> >> >Subject: Re: [vintagvw] 68 bug Headlight problem >> >Date: Wed, 08 Aug 2007 06:24:21 -0500 >> > >> >Hi, Asad, >> > >> >Good to hear that you found the trouble. If it was my car, I would >> >replace the loose #30 terminals with new ones to avoid future problems. >> >Those connectors work on pressure between the connector and blade to >> >make a "gas-tight" contact. If they get too loose, the contact will be >> >high resistance, and get hot. >> > >> >Petroleum jelly will evaporate too - just takes longer. If you have the >> >plastic cover over the fuses, they stay pretty clean. An alternative is >> >wheel bearing grease, but the jelly is neater and cleaner. You don't >> >have to use a lot of the stuff - just enough to make a film over the >> >part of the terminal where the contact is. >> > >> >Chuck Kuecker >> > >> >asad ishaque wrote: >> > > As a matter of fact day before yesterday in the evening I tinkered on >> > > my dub.....that was after I sent out the querries..... >> > > >> > > Had to get my bug on the road since I did not feel like borrowing >> > > dads ride for going to work that night. >> > > >> > > Had a spare brand new headlight relay left over from the resto of >> > > my second 68 bug. >> > > >> > > Simply replaced it and yes!! Everything picture perfect again! >> > > >> > > I found that four out of five, except for the number 30 terminals >> > > can be rocked on the relay. Maybe this was causing probs. The spade >> > > connectors were all tight and snug, in fact so tight that I got the >> > > wire off instead of the connector while pulling one. >> > > >> > > The fuse box does hold the key to a lot of mysteries I have also >> > > learnt. I clean up the terminals with emery cloth like you say but go >> > > on to coat it with Phillips contact cleaner, which I have seen >> > > evaporated over a short while. Maybe petroleum jelly is a better >> > > option. But would it not create a mess by trapping dirt?? >> > > >> > > Best regards, >> > > >> > > Asad >> > > >> > > Karachi, Pakistan. >> > >> >_______________________________________________ >> >vintagvw site list >> >vintagvw@lists.sjsu.edu >> >http://lists.sjsu.edu/mailman/listinfo/vintagvw >> >>_________________________________________________________________ >>Tease your brain--play Clink! Win cool prizes! >>http://club.live.com/clink.aspx?icid=clink_hotmailtextlink2 >> >>_______________________________________________ >>vintagvw site list >>vintagvw@lists.sjsu.edu >>http://lists.sjsu.edu/mailman/listinfo/vintagvw > > _________________________________________________________________ > Puzzles, trivia teasers, word scrambles and more. Play for your chance to > win! http://club.live.com/home.aspx?icid=CLUB_hotmailtextlink > > _______________________________________________ > vintagvw site list > vintagvw@lists.sjsu.edu > http://lists.sjsu.edu/mailman/listinfo/vintagvw > _______________________________________________ vintagvw site list vintagvw@lists.sjsu.edu http://lists.sjsu.edu/mailman/listinfo/vintagvw
