HELP!!! Weird Headlight Problem (01 Caravan)

[flogtun]

I too have a 2001 Caravan SE. My headlight went out so changed the bulb but that didnt work. took it to the garage who stated it was the front control module. $450 just for the new part. My mechanic managed to run a bypass on the lights so I could still use them just not on High beam, which worked fine for 3-4 days. Then when driving home my lights suddenly started to dim briefly repeatedly, then my engine coughed.....about 10 mins later around 11pm in the middle of my sub division nearly home my horn started sounding like an alarm (I dont have a car alarm though) I turned the ignition off and took the keys out but I could not shut the horn off. Eventually i found the fuse/switch for it under the hood on drivers side (after searching using only the light from my cell phone lol). The next day i took it into the garage again and then could still not fix the problem and again said i need a new FCM. I was told by them i shopuld be able to pick one up online for about $100, so trying to look today. Last night on the way home at night my lights suddenly started to flash light a cop car and had to disconnect the battery overnight to shut them off. When i connected the battery this morning, it seemed to have reset the lights, but im sure in the next day or so the same would happen again. Am going to try to take the FCM off and clean and twist the connections as per previous thread. Hope this works for me. Im fed up with this blinking van now. Watch this space. Thnks to all for the suggestions prior to this thread.......... New member

[patternbuilder]

glad i found this. we've had the same problem on our 2002 dodge grand caravan which was manufactured in canada. one headlamp works on the passenger side, and when the high beams are used, only one headlamp works on the driver's side. we were quoted $700 for the repair from a Dodge dealer in Wheaton, MD - which probably as much $ as the whole van is worth, really.

the dealer spent an hour determining that it was, in fact, the FCM. however, until i read this, i had no idea we could try to to pull it off and clean the contacts. i will try this and let you know how it goes!

-p

[danielsatur]

I like using a small brass bristle brush, CRC electrical cleaner for cleaning, and dieletrical grease for protection.

[cara01]

Originally Posted by Walter Zoomie

This works! On my '01, I pulled the module, cleaned and lightly sanded the pins with fine sand paper, then carefully gave all the pins a slight twist (using needle nose pliers) for better contact. No problems since, and cost nothing but time and a little aggravation.

After reading several posts I decided to remove the module (4 screws & 2 minutes later it was in my hand) I gave each pin a slight twist then replaced the module.So far everythings working fine,although it has only been 15 minutes since I've replaced the module.I've got my fingers crossed that it's problem solved.Thank You so much for all your posts.

[Cripple]

For those of you buying modules and what not, you have been ripped off. I just finished working for Chrysler and branched out on my own. I was a recall specialist for 12 years.
Your problems with your headlights are all wiring issues. If you follow the harness you will see it has a bend near your battery box. This is your issue. One of 2 white wires with stripes has corroded or cracked. Replace the wire of take out harness, clean up and repair the wire. There is a very simple fix for this and you dont need to buy anything other then a small piece of wire and some electrical tape or shrink wrap. If you need detailed instructions or diragrams for this email me or contact me through the site. my email is clarkmanuel@nl.rogers.com. Remember this is not an expensive fix. You can do it yourself for about 20 dollars and you dont need to be a mechanic. You only need to join a wire.

[harleybudlj]

can someone show me a picture of the control module or where it is for sure on the van ?? Not sure what im looking for ??

Lj

[RIP]

Originally Posted by harleybudlj

can someone show me a picture of the control module or where it is for sure on the van ?? Not sure what im looking for ??

Lj

The FCM? Go to the 3 minute mark in this video and pause it. You'll be looking at the battery and the fuse box (IPM) to the right of the battery. The FCM is the silver box on the front of the fuse box: http://www.youtube.com/watch?v=i3DRaWGSobc

This only applies to 4th generation 2001-2007 minivans.

[harleybudlj]

Originally Posted by RIP

The FCM? Go to the 3 minute mark in this video and pause it. You'll be looking at the battery and the fuse box (IPM) to the right of the battery. The FCM is the silver box on the front of the fuse box: http://www.youtube.com/watch?v=i3DRaWGSobc

This only applies to 4th generation 2001-2007 minivans.

Thanks for the info.. I'm sure I know were it is now.. Thanks again. Lj

[harleybudlj]

I fixed the headlight problem .. I took off the FCM on the fuse box and gave each of them metal terminals a slite turn so they would connect better when plugging back in.. I had my fingers crossed and it worked.. Thanks for all the info.

Lj

[slingerkb]

I had the same headlight problem. I had another van for parts, I took off the fcm from the parts van, cleaned up the terminals and placed on my van. The lights worked but my wife noticed later that day that the front and rear windshield washers were not working. I thought that maybe the fcm had something to do with this as well because the fuse was good and there was no noise coming from the windshield washer motors. I cleaned the terminals up on the fcm I took off and put it back on the van and now lights and washers are working. If anyone has a problem with their windshield washers, the fcm can definitely be the cause. A cleaning of the terminals can be a much cheaper alternative than buying a new one. For anyone wanting to know where the fcm is located, it is that silver box in front of your fuse panel under your engine hood on the drivers side near the battery. Just take the cover off the fuse panel and remove the 4 torx screws in front. Then pull the fcm forward which will unplug it from its terminals. You may have to rock it slightly as you pull forward to make it easier.

[mrtwidget]

I made an account just for this post. I used this post as a troubleshooting guide for the same issues most of you are describing as I repaired this issue.

Refers to 2004 Chrysler Town and Country

SHORT VERSION:
The problem is broken wiring in the headlight wiring harness. Replace defective wiring.

LONG VERSION:
The issue began when the passenger side low beam headlight went out - high beam side still worked. Replacing the bulb did nothing. I then located and removed the FCM module, per suggestion here, but all the contacts looked clean and corrosion free. I wasn't convinced that was the issue.

So I decided to check continuity of the headlight wiring harness on the low beam +12V line. I traced the wiring harness back to the IPM fuse box and disconnected the headlight wiring harness clip from the IPM. I traced the low beam wire and tested the resistance from each end of the harness.

There was noticeable resistance that indicated possible faulty/broken wiring, so I decided to snip the wire at both ends and replace it with a new piece, just to confirm the problem was in the wiring. It worked.

So to make it permanent, I followed the headlight harness path and zip tied the new wire to it, wired it back up on each end, and now the headlight is working fine.

P.S. Upon troubleshooting this issue, and adding additional stress to the wiring harness from moving it around, the same passenger side running light/blinker went out. Because both the running light and blinker stopped working I suspected the ground wire was the culprit. Tested continuity like before and it was wide open.

Might just want to replace the entire harness.

[Eco_Inventions]

I have the same issue after calling several dodge dealers and being told to change the front control module & the fuse box and then re-programming three computers at a cost of almost $2000.00. I started looking for solutions, but I am not a mechanic.

I had the FCM changed and no luck, I did not try and twist the terminals yet.

I was just told a simple fix : locate the power wire for your daytime running lights and then locate the power wire for your night time headlights and connect them together with a wire and connectors etc.

Then when you turn on your daytime driving lights, your night time headlights will work, but do not forget to turn them off.

There are countless Dodge mini vans with this issue, I think there should have been a recall.

[timetraveller]

I had the exact same situation as you described. Being somewhat skeptical of the "fix" described concerning the (FCM) Front Control Module, I went ahead and removed the FCM. Following the post to clean the spade connectors with emery cloth, they did indeed have a chalky type residue on them, I reinstalled and still the problem persisted. In desperation I took the FCM off again and cleaned them more vigorously, and this time did indeed give the spade connectors a very slight twist for a more interference fit. HOORAY! The "fix" took care of the problem.

[Noshanksallowed]

Good afternoon gentleman, so I took my fcm off, cleaned the prongs. Everything worked fine. 2 days later it don't work again. I can take the fcm 1/4-1/3 of the way off and everything works fine. So here's my question, I put the screws in to hold it in place being 1/4 of the way unplugged. Can I leave it this ways or may shit go haywire? Do you think the screws will come lose?

[timetraveller]

I suggest cleaning one more time and then give the spades an ever so slight "twist" so that there is more of an interference fit in the connection. The "twist" was the final solution in my case.