'90+ Daytona Headlight Module repair

[patrickjengram]

I just completed the headlight module repair on my '90 Daytona C/S. I searched through the posts on this repair and studied the pictures posted of the '89 and older Daytonas, saw the thread that located the module on my car, then pulled it out today. I didnt have to even pull the knee bolster down, just looked up under the dash and found it clipped onto the brace as described.

I found a couple bad solder joints, mostly where the relays install into the circuit board. I did find one bad joint where one of the connector's pins is soldered to the pcb. I flowed new solder onto all them, good or bad, just be on the safe side. I installed it back in the car and the headlights are now working fine.

Did I mention that I know have a couple headlight motors to get rid of since I will not be installing them?!

I took pictures of the module and components as I did the job, but do not have that photobucket thing to upload them. If anyone wants to, I can email them the pictures and they can find a way to get them on here.

Key notes of this job:

The module is rectangular in shape, flat on 5 sides, but stepped on one of the sides. I used a razor blade to cut the box at what looked like a casting line, and then was very happy when the "cover" actually popped right off. The gel stuff on the inside was not liquidy at all. One section of it at the connector comes out on its own. The whole pcb is completely encased in the gel all the way around. I sliced the gel around the perimeter of the pcb and peeled the whole side off the pcb in one whole piece. It stuck in some spots but I pushed it loose with a small screwdriver and kept it intact.

The circuits are not exposed on the side the pins come through, so it would be pretty tough to mess it up. 5 minutes to clean up the board of residual gel and 5 minutes of soldering and it was done. I put the piece of gel back in the module case, put the module back in, snapped the cover on, taped the seams with black electrical tape, and it was done.

Even though soldering and electrical repairs dont bother me, this ended up being easier than I thought, and extremely satisfying when seeing them actually go down for the first time!

[ValleyBoy]

I'm new to the group, but have been looking for some help on my 87 Daytona Shelby Z. Problem: no dash, tail or parking lights. I know all bulbs are good, the fuse is good, replaced headlight switch and that didn't work. I had them working for a while when I pulled the headlight switch to parking lights and fiddled around with it but as soon as I pulled switch to headlight mode, parking, tail and dash lights went out. Right now I can not even get lights to woek by fiddling with switch. I don't have schemetic for this car so I don't know what else could be causing problem. Could you email the info. on the head light module?
Thanks,
Dan D.

[1970 beepbeep]

Patrick, you the man!!! After receiving your e-mail pics I started working on it. My cost w/ all parts (soldering gun,electrical tape,epoxy,and solder) $27.55 OEM part list $102.55 Thanks again Patrick


Rick

[patrickjengram]

Dan, without a schematic, I'd be guessing that it sounds like your switch is on the fritz. I do not know if that year has a bcm, but I doubt it.

Send me a pm with your email address and I can send you a couple of pics right from my phone.

Rick, glad you had success with your repair. Great feeling when they work, aint it?!
Patrick

[ValleyBoy]

I also thought it was the switch and after trying 3 from the junk yard and 1 new one, I've decided it is something else. Appreciate and help you can provide.
Thanks,
Dan D.

[charger R/T]

Quote:

Originally Posted by ValleyBoy I also thought it was the switch and after trying 3 from the junk yard and 1 new one, I've decided it is something else. Appreciate and help you can provide. Thanks, Dan D.

Start a thread in the electrical section on your problem and you will get alot of help with it.
Tim

[Reaper1]

I want to point out that I've come across what I beleive is a later replacement HCM and the potting material is rock hard! It is more like a hard plastic than the old stuff. I've not attempted to get to the PCB yet, but I think I'm going ot end up breaking it when I do.

[ValleyBoy]

Charger R/T
After changing the headlight switch with 3 used and 3 new and the plug, I decided the head light switch wasn't the cause of no trail, parking or dash lights. I thought I would try changing the head light mogule, because the line that powers the parking lights is connected through the plug. At first the lights did not work, but after letting new module insatalled for a while, the lights started to work. I'm crossing my fingers and hoping that this module was the problem.
ValleyBoy

[charger R/T]

funny I just got here and I just posted my thoughts on the module in your other thread.
Tim

[patrickjengram]

That's screwy. You could jump the old headlight switch and they would work, but installing a new one didnt. The headlight switch sends power to the module according to the wiring diagram. So you had no power coming into the module but putting a new module on somehow fixed it? I do electrical work in my sleep but this baffles me.

I'm not tearing you a new one, I just cant figure this one out!
Patrick

[Reaper1]

There is a realy bank in the dirver's footwell...I'm wondering if by chance he didn't disturb something having to do with that? I don't have the diagrams sitting in front of me, but I'm 99 positive that the switches on the bezel don't control anything directly, including the HCM. They all use a realy, then where applicable go the the BCM which sends out signals from there....

[ValleyBoy]

Guess what guys? You can all sleep easy tonight. The problem is not the switch nor the module or the plug. It's the fuse block!!!!!!!!!!!!!!!!!! Tonight I was putting everything back together again and when was all done, guess what, NO LIGHTS!!! My jaw dropped, then I retraced my steps and realized that I moved the fuse block. So I moved it again and the lights went on, moving the block makes lights go off and on. There is some bad connection so I will try to isolate it and make repair. What a trip trying to find this problem, but it appears that I have really isolated it now. Thanks for all your help.
Dan D.

[jdmr111]

Could you send the pics to john.meyer1@comcast.net ??I have a 90' VNT Shelby w/the same trouble. Thanks

[ValleyBoy]

John - Are you looking for pics of the fuse block or what? I have just been going by pics that are available in the posts.
ValleyBoy

[CrAzYMoPaRGuY]

I also did the solder fix on my headlight module after finding the other thread on this forum, it was easy and worked like a charm.

I had two spare good modules, so I'll just keep the repaired one as a spare, but it's good to have info like that on TurboDodge!!!!!!