01 GC headlight problems

[N8SBlaze]

hi there,
My GC has developed the problem of the DRL coming on the Drivers side and not the passenger side and then switching when putting on the low beams and switching again with the Hi beams. I searched this forum and read several posts of the exact same problem. I did not see any real final solutions in those posts though. I tried disconnecting the battery and cleaning the cables and posts, diconnected what I am guessing is the BCM (in front of the battery and fuse block?) and checked the connections. The battery was disconnected for 10 minutes to reset the BCM, anyway so far none of this has worked. Any updates or further suggestions would be appreciated.
Thanks
N8

[Cntrysthbst]

from what I've read there is a module that controls this and is not part of the PCM. when replaced it was fixed from what I remember. I can't find it yet or know where the location is. Will update if I find the info.

[N8SBlaze]

Last night while driving I noticed that all my lights suddenly work again. Weird. I suspect the problem will rear its ugly head again though. Again if anyone has any more info, it would be appreciated.

[Cntrysthbst]

There is a module that runs the lights, its in front of the fuse/relay next to the battery. If it is causing the problem they will have to replace it, or you can. It can't be flashed. If your inside lights/dash lights are doing the same you can get it flashed at the dealer, that one is the BCM. Also, do make sure your battery is good, mine tested good at 4 different advanced suto stores. I couldn't figure it out so I took it to the dealer where they told me it had 12.67 volts which everyone told me was good. It's not, according to the dealer, it's to low. I had them replace the battery and lights are perfect. They also told me everything runs through the battery, the alt. just charges the battery, so it's very important to have a good battery. It can cause all kinds of electrical issues. I had lights coming on on the dash, airbag/abs/security/, on top of engine running like crap, shifting different, and all cause of a low battery. Everything is fine now.

[N8SBlaze]

Cntrysthbst,
Thanks for getting back to me on this. What does it mean to have the BCM flashed? My lights are still working for now. Thanks for the info about the battery voltage, the battery is only a year or two old but I will keep an eye on it.

[Javie]

Originally Posted by N8SBlaze

hi there,
My GC has developed the problem of the DRL coming on the Drivers side and not the passenger side and then switching when putting on the low beams and switching again with the Hi beams. I searched this forum and read several posts of the exact same problem. I did not see any real final solutions in those posts though. I tried disconnecting the battery and cleaning the cables and posts, diconnected what I am guessing is the BCM (in front of the battery and fuse block?) and checked the connections. The battery was disconnected for 10 minutes to reset the BCM, anyway so far none of this has worked. Any updates or further suggestions would be appreciated.
Thanks
N8

2001 Dodge Grand Caravan headlight issue updated. Well now that it has been a couple of weeks and the lights are still working properly on the van. So that tells me that the problem is with the FCM. I have since also done the same thing to a friends van ( 2002 though) and for the last 9 days, it has also worked without a glitch.

So, for anyone who was thinking of running off to the dealer and forking out hundreds for part(s) and labour. Don’t do it. Chances are, removing the FCM yourself, cleaning it, replacing it will save you hundreds. Forget wasting your time trying to get it done through Dodge. It takes all of 10 minutes and your good to go.

In case anyone wants to know: It is a very simple process.

• Just remove the plastic cover over the PDC ( which is the black cover beside the battery. )
• Looking at the front of the PDC is a silver housing with 4 torx screws.
• Remove the 4 screws.
• Pull out the FCM housing. ( It separates from the PDC )
• Looking at the FCM, you’ll see 2 rows of needle pins, and 1 row of flat pins.
• The flat pins are the culprits, what I did was use a fine small file and cleaned both sides of the flat pins only. They appeared to have a white coating of buildup on them.
• Then I took small needle nose pliers and gave each flat pin a very small slight twist. Not to much, but a noticeable twist.
• I re-inserted the FCM into the PDC, tighten back the 4 torx screws and voila!
• Lights have been on for the last 2 weeks and 5 days now.

Now, if I could just get my power window on the passenger side to work 100 % of the time as opposed to 75 % of the time, I’d be a happy camper.

[N8SBlaze]

Originally Posted by Javie

2001 Dodge Grand Caravan headlight issue updated. Well now that it has been a couple of weeks and the lights are still working properly on the van. So that tells me that the problem is with the FCM. I have since also done the same thing to a friends van ( 2002 though) and for the last 9 days, it has also worked without a glitch.

So, for anyone who was thinking of running off to the dealer and forking out hundreds for part(s) and labour. Don’t do it. Chances are, removing the FCM yourself, cleaning it, replacing it will save you hundreds. Forget wasting your time trying to get it done through Dodge. It takes all of 10 minutes and your good to go.

In case anyone wants to know: It is a very simple process.

• Just remove the plastic cover over the PDC ( which is the black cover beside the battery. )
• Looking at the front of the PDC is a silver housing with 4 torx screws.
• Remove the 4 screws.
• Pull out the FCM housing. ( It separates from the PDC )
• Looking at the FCM, you’ll see 2 rows of needle pins, and 1 row of flat pins.
• The flat pins are the culprits, what I did was use a fine small file and cleaned both sides of the flat pins only. They appeared to have a white coating of buildup on them.
• Then I took small needle nose pliers and gave each flat pin a very small slight twist. Not to much, but a noticeable twist.
• I re-inserted the FCM into the PDC, tighten back the 4 torx screws and voila!
• Lights have been on for the last 2 weeks and 5 days now.

Now, if I could just get my power window on the passenger side to work 100 % of the time as opposed to 75 % of the time, I’d be a happy camper.

Hey Thanks for the advice. My lights are still working, but when I get a chance I will take a look at the flat pins on the FCM, it probably won't happen till next week though. Thanks again

[Cntrysthbst]

Interesting, that sounds like some good info Javie, will do a check on mine just to see. I will check into the BCM being flashed part and post back.

[vipergg]

If you are going to do this I would pull the battery cables first .

[Cntrysthbst]

Yes, I did pull the cables and everyone that does do this should to to prevent damage to the module. I had to remove my battery from the van and lift the IPM fuse relay center up to get access to the bottom left screw that the PCM was blocking.

The FCM is the module that runs the exterior lights, DRL too. This is the one that the dealer told me I will need to replace if the lights keep flickering because it can't be flashed. But before you get to that point, do make sure the battery is good, grounds are good, and cleaning the flat pins on the FCM. That was a good idea, I didn't see any hot spots or any charring but I feel better knowing the contacts on the FCM are better. I put a light coat of electric grease on the pins too.

[N8SBlaze]

Originally Posted by Javie

2001 Dodge Grand Caravan headlight issue updated. Well now that it has been a couple of weeks and the lights are still working properly on the van. So that tells me that the problem is with the FCM. I have since also done the same thing to a friends van ( 2002 though) and for the last 9 days, it has also worked without a glitch.

So, for anyone who was thinking of running off to the dealer and forking out hundreds for part(s) and labour. Don’t do it. Chances are, removing the FCM yourself, cleaning it, replacing it will save you hundreds. Forget wasting your time trying to get it done through Dodge. It takes all of 10 minutes and your good to go.

In case anyone wants to know: It is a very simple process.

• Just remove the plastic cover over the PDC ( which is the black cover beside the battery. )
• Looking at the front of the PDC is a silver housing with 4 torx screws.
• Remove the 4 screws.
• Pull out the FCM housing. ( It separates from the PDC )
• Looking at the FCM, you’ll see 2 rows of needle pins, and 1 row of flat pins.
• The flat pins are the culprits, what I did was use a fine small file and cleaned both sides of the flat pins only. They appeared to have a white coating of buildup on them.
• Then I took small needle nose pliers and gave each flat pin a very small slight twist. Not to much, but a noticeable twist.
• I re-inserted the FCM into the PDC, tighten back the 4 torx screws and voila!
• Lights have been on for the last 2 weeks and 5 days now.

Now, if I could just get my power window on the passenger side to work 100 % of the time as opposed to 75 % of the time, I’d be a happy camper.

Thanks again for this advice. My headlight problem reoccuerd this morning and so I tried what you recommended. I had that same white build up/coating that you had mentioned. I cleaned , gave a slight twist, applied a small amount of dialectric grease to the pins and reassembled. Unfortunatly form me this did not solve the probelm this time. So the search continues.

[N8SBlaze]

Originally Posted by Cntrysthbst

Yes, I did pull the cables and everyone that does do this should to to prevent damage to the module. I had to remove my battery from the van and lift the IPM fuse relay center up to get access to the bottom left screw that the PCM was blocking.

The FCM is the module that runs the exterior lights, DRL too. This is the one that the dealer told me I will need to replace if the lights keep flickering because it can't be flashed. But before you get to that point, do make sure the battery is good, grounds are good, and cleaning the flat pins on the FCM. That was a good idea, I didn't see any hot spots or any charring but I feel better knowing the contacts on the FCM are better. I put a light coat of electric grease on the pins too.

Cntrythbst,
Do you know if the FCM can only be bought from the dealership or can this be purchased at an auto parts store? If the FCM controls the headlights, then I guess my next step is to price out this piece.

[N8SBlaze]

In case anyone is interested, I finally got to the bottom of my headlight problem. While searching around under the hood I loosened the four screws on the FCM and wiggled it while it was still plugged in and the one headlight that was out suddenly came on. I then repeated the procedure posted by Javie above, and it worked. I had tried the procedure once before but it did not work for me. I gave the flat pins on the FCM a little more twist this time. The FCM did not plug back in as easy but once back in I tried the lights and they both worked even when I wiggled the FCM. I was sooo close to giving up and taking it to the dealer. I am glad this forum is here.

[Cntrysthbst]

Yes very interested, every bit of info helps! Thanks for posting back on this and sorry for not getting back to you sooner, seems everything goes into the bulk section in my emailbox.

Dealer was only option. It cost $180.00 installed. Mine was a ground problem which caused the FCM and a couple other things to go bad. I did sand and twist but the lights still flickered.

I am glad to know you have fixed it, life's much better when problems go away, and knowing you saved some .

Before anyone thinks they need a new one, read what Javis wrote, do check the pins, lightly sand them and turn the pins somewhat to see if this fixes your problem. If it doesn't -- try again!