Instrument cluster illumination - semidead

[Slonopotam]

Hi,

96 XJ. Cluster illumination lamps mostly do not work. When the switch is in ON position - never work. When in PARK - I can jiggle the switch a bit and catch a position, where both the lamps and park lights are lit.
Obviously, there was something wrong with the switch. I pulled it out to get the P/N off it. Tested, just to be sure. The switch worked very reliably under test. That is, I jiggled a lot and I could not make it misbehave!

Is it possible there is some kind of an automatic curcuit breaker inside the switch, which detects high current ?

It looks like the switch powers up a relay, but I could not find it on the diagram. What else, besides cluster lights and headlamps, this switch controls ?

Thank you,
Andrey

[5-90]

Andrushka..

Going through my 1996 FSM, here's what I've been able to find out:

Starting on 1996XJ FSM p.8W-44-6 (Interior Illumination...)

PDC fuse 13, 40A via Red/White wire to fuse 15 (15A,) then a Orange/Black wire to the headlamp switch.

Out from the headlamp switch via Orange/Black wire through Fuse 19 (5A) into splice S208.

Splice S208 feeds a batch of 20AWG Orange/Black wires for switch aillumination, the LCD Illumination Relay (which seems to just power the radio lights,) and the IP (fused panel lamps dimmer SW signal.)

The only relay that seems to be involved is the one for the radio lighting - so you may not have a switch problem - it may be a connector problem, as in a spade tongue has started to loosen. A little work with a small flat screwdriver (or very fine needlenose pliers!) would serve to restore that connection - start with the Orange/Black wire coming out of the switch, but check them all. I've been able to test the tightness of the contact using a .250" male spade terminal blade, and that would allow you to point out what all needs to be tightened, and work accordingly.

5-90

[Slonopotam]

so you may not have a switch problem - it may be a connector problem, as in a spade tongue has started to loosen.
5-90

Thank you. I can do that. How does it explain that jiggling the handle of the switch helped ? That is, neither the connector nor wires were moved, just the handle inside the switch.

I also heard some noise when the lights were lit, but I could not understand where it was coming from.

Thanks,
Andrey

[90xj06]

i replaced my lights with blue LED's :sunshine:

[5-90]

Thank you. I can do that. How does it explain that jiggling the handle of the switch helped ? That is, neither the connector nor wires were moved, just the handle inside the switch.

I also heard some noise when the lights were lit, but I could not understand where it was coming from.

Thanks,
Andrey

Because the handle is going to be more or less mechanically connected to the wiring contacts, the typically move slightly when you move the switch actuator (pull handle, press button, toggle bat, whatever.)

And, when you test with a meter of some sort, you probably have a solid mechanical connection - either by pressing the meter lead against the terminal blade, or by the crocodile clip clamped on the blade. If it's an external connector issue as I've mentioned, you won't turn that up with a meter, since you're going to be applying some effort to make sure you're making contact. Make sense?

5-90

[Slonopotam]

I finally got back to it.

I took the switch out again and looked at connector - it was fine. I then decided to play stupid and pull out the fuse 15, which goes to B2 pin of the switch. I thought, if I can jiggle the switch and make the lights work, it must be the switch. I was wrong. It turned out the fuse 15 was blown and by jiggling the switch I was connecting everything to B1, which is not protected by a fuse. I tried to put a new 15A fuse. As soon as I turned the switch to park, the new fuse made a small firework and said good bye.

A couple of hours later, with a mess under the hood, torn trim panels and connectors disconnected all around the jeep I found that the receiver hitch wiring was smashed and shorted.

Stupid me.

Thanks 5-90 for advice.

[5-90]

Stupid me.

Hardly. Just a problem outside your experience. Confucius say, "Experience is something you don't get until just after you need it..."

Now, you've expanded your experience. It's not something you'd figure out from looking at electrical diagrams anyhow - they're logical, not physical...

Glad you got it sorted.

5-90

[Pioneer84]

Hardly. Just a problem outside your experience. Confucius say, "Experience is something you don't get until just after you need it..."

5-90

True Vary True.