Lowbeam headlights do not work

[jberenyi]

I started the 1996 Grand Caravan one morning and the lowbeams did not turn on. The highbeams work fine. Here is what I have done with no success yet. I replaced the headlight switch ($85!), checked all fuses and swapped the highbeam and lowbeam relays. I obtained the service manual from the dealership on loan but I am lost on how to effectively troubleshoot this problem. I jumped the wires on the headlight switch before the relay and my lowbeams lit up so I know they work. The problem I believe is between the switch and lowbeam relay but I don't know how to troubleshoot it the correct way. The odd thing is that my intermittent wipers are acting funky too and I replaced it ($76!) thinking it was a separate problem from the lights. It still acts funky but only in the intermittent mode. Not in any other postion. Please help...

[gforster]

Ok first you have to remove the wiper motor and take the cover offf it and clean the metal contact ring inside... if they aren't stopping or stopping erratically only in int. mode then that is the prob - not the switch i tried that $$$$!!!!! I'll check into this headlight thing OK?

Geoff

[jberenyi]

Originally Posted by gforster

Ok first you have to remove the wiper motor and take the cover offf it and clean the metal contact ring inside... if they aren't stopping or stopping erratically only in int. mode then that is the prob - not the switch i tried that $$$$!!!!! I'll check into this headlight thing OK?

Geoff

Great...one down and one to go. I hope I figure out this headlight thing before Monday morning so I can go to work without having to use the highbeams.

[gforster]

OK remove the shroud on the steering column - three screws going up from underneath and seperate the halves - easy. You say the hi beams work so that tells me the Body control module is sending ground signal tho the dimmer switch. Plugged into the multi function pogo stick you should see a whole bunch of wires - unplug it if you like. the ones you are interested in are: Orange with white stripe, white with light green stripe, red with yellow stripe, and black. Found them? Good. You should use a jumper lead with a fuse here just to be safe.... Connect one end of the jumper to ground, turn on the headlight switch, and probe the orange with white stripe - if lowbeams come on, chances are real good it's the pogo stick. The Body Module sends a ground signal for lights on to the dimmer part of the pogo switch using the red with yellow stripe wire. Look at the manual you have and focus on the headlamp dimmer switch you will see all this. I almost gaurantee your pogo stick is faulty

[jberenyi]

The thing you're calling the pogo stick...do you mean the wiper/turn signal stick? If so, I already replaced it with a new one and there was no change.

[gforster]

ok that shoots that theory out the window - I'm on it just give me a sec.... a real brain teaser eh?
lol

[jberenyi]

Sure appreciate your effort. I'm not sure if this is an issue but about 2 years ago my wife was in an accident on the driver's side which is where the wiring harness is located. Could this be an issue?

[gforster]

Yes!!!!
you still need to ground that orange wire with the white stripe at the terminal on the pogo stick. If no low beams come on there is a problem between here and the relay in the power distribution box under the hood. I suspect the bulkhead connector, but we need to check the continuity of that wire to the relay. Maybe you can just bridge a new piece in under the power distribution center and go right to the plug at the dimmer switch...

[jberenyi]

Okay...I jumped the orange/white wire after removing the plug from the pogo housing. There was no light or relay sound. Can this be done with the plug undone? I will attempt a bridge next.

[jberenyi]

You are the man!!!!!!!!!!!!!! I jumped the orange and white wire underneath the power dist. box and the lowbeams came on! At least we know that the break is somewhere between the relay and the pogo. Do you happen to know where the bulk head connector is? I will try to isolate the break but if I can't find it maybe I should run a separate line?

Thanks so much for your help...I don't know what I would have done without you and this forum.

John

[gforster]

Thanks John you are very cooperative - glad I can help Look for a cut wire (collision damage) but it's gonna be tough to find there are a heck of a lot of wires in there. The bulkhead connector is way up behind the underdash fuse panel and is a bugger to get at never mind dissasemble. I'm thinking just run a new wire and bypass the break... I hope you are working in the warmth - it's -12C here in BC Canada. I've never had the bulkhead connector apart so i can't help you there. But hey, at least we have the problem isolated now!

[jberenyi]

Geoff,

I did what you suggested and ran a wire from the relay box to the pogo stick. It works great!!!! And the wipers work great too! Good thing I have a heated garage. Again, thank you so much....my wife thanks you too.