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  1. #1
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    GEN I fixes, trouble shooting, and minor repairs

    I modified this post in that I am going to simply track all the efforts it takes to get a low mileage (3,600) 1995 vehicle back into tip top shape for car shows, safe driving, and on the market for sale.

    I will be posting each of the issues I encounter, what I like and dislike about the car, what I plan to do to resolve the issue, and will be soliciting the help of the forum to get this vehicle done.

    I will also post my new GEN V restoration project under the GEN V forum later this month. Currently, I plan to build another GEN V from the ground up into a MEDUSA... more to follow on that project later.


    Current issue being solved; GEN I lighting distribution issues;

    1) no headlamps
    2) no tail lamps
    3) no interior dash lights
    4) no fog light power

    What I do have is;
    1) power to the mirror light for internal lights - controlled by the lighting nob
    2) power to the mirror light when the doors are open
    3) chimes to inform me that the lights are on when the power is off
    4) Brake lights when I his the brakes
    5) Hazard lights when I hit the hazard button

    What I did so far;
    1) pulled all the fuses and checked them out
    2) found a bad fuse link wire at the main power distribution node under the hood - fixed
    3) pulled the fuse switch and checked out the contacts - they look new
    4) pulled the light switch controller and checked for corrosion or bad connections - looks brand new


    I am stuck at this point and am pulling out the multi-meter to start testing individual power lines but am hoping there is a easy fix that I am missing.

    This is my first GEN I vehicle I am working on. Car only has 3,600 miles
    Last edited by viperguy69; 04-09-2020 at 09:00 AM. Reason: restoring the GEN I back to orginal condition
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  2. #2
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    Probably the headlight switch. They usually have multiple circuits in them so one thing could be good while others are bad ref the safe switch. A wiring diagram would be your best friend right now. The Gen 2 manuals have great diagrams. Never seen a Gen 1 book.
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  3. #3
    Enthusiast 99RT10's Avatar
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    Gen 1 HL switch is notorious for overheating and melting. I have had to replace several. Like Dave said, start there.
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  4. #4
    Sounds like a HL switch to me. I've done a couple myself. Don't be surprised to find something like thisVipergenHL.jpg

    You're in luck the 90s Neons are the exact same plug.

  5. #5
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    Nope, mine looks brand new... I will get a picture here shortly.

    One correction, I guess it was a little too sunny this afternoon, that fuse line wire fixed:

    1) Interior instrument Lights
    2) rear tail lamps
    3) small headlamp lights
    4) marker lights - despite them not on last night but the hazards working is still confusing to me.
    5) Head lamp brights work if you pull the windshield wiper switch back but they will not stay on.

    What is still not working:
    1) Fog lamps (switch looks new and I unplugged it and reseated it)
    2) Main head lamps (low beams) - getting the multi-meter out again...

    20200402_204051.jpg
    20200402_204021.jpg
    20200402_204045.jpg
    Last edited by viperguy69; 04-02-2020 at 09:03 PM.
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  6. #6
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    [QUOTE=Viperrt96;406906]Sounds like a HL switch to me. I've done a couple myself. Don't be surprised to find something like thisVipergenHL.jpg

    Thanks, that looks terrible! I wonder if that is what happens when you replace the fuse link wire with a normal wire?

    Mine looks almost new... I will try to get a better picture tomorrow.
    Last edited by viperguy69; 04-02-2020 at 11:34 PM.
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  7. #7
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    Quote Originally Posted by dave6666 View Post
    Probably the headlight switch. They usually have multiple circuits in them so one thing could be good while others are bad ref the safe switch. A wiring diagram would be your best friend right now. The Gen 2 manuals have great diagrams. Never seen a Gen 1 book.
    Thanks, I will see what I can find in a PDF file on the GEN 2 then

    - - - Updated - - -

    Quote Originally Posted by 99RT10 View Post
    Gen 1 HL switch is notorious for overheating and melting. I have had to replace several. Like Dave said, start there.
    I was going to buy a set of these last night... looked like the right one!

    https://www.ebay.com/itm/Head-Light-...AAAOSweI9doUZb

    Upon closer inspection I noticed that this one was missing two contacts... so, I ordered this one instead as I liked the fact that it had copper contacts:

    https://www.ebay.com/itm/HEADLIGHT-H...72.m2749.l2649
    Last edited by viperguy69; 04-04-2020 at 07:39 PM.
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  8. #8
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    Alright, got the switch out and moved the components around a little and wallah, the headlamps are on! But, the instrument cluster is now dead. Hopefully the new switch will be here this weekend.

    20200402_233253.jpg
    20200402_232822.jpg
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  9. #9
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    Possibly heat damage here inside switch where you can't see it.

    Untitled.jpg
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  10. #10
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    Quote Originally Posted by dave6666 View Post
    Possibly heat damage here inside switch where you can't see it.

    Untitled.jpg
    I agree, I saw that as well. However, I am thinking more in line with heat damage as it relates to corrosion as the vehicle has been in Tampa, FL for about a decade. All the contacts look like they have a salty scale on them. I bet that is what it looks like in the inside. Once I get the new one I will be taking this one apart to see where the malfunction is.
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    Here is a source for fusible link wire just in case someone was looking for it. The wire was broken at the connection to the lug. If you have a link wire that is blown all you need to do is tug on it and it will stretch like those Mr Stretch (or was it Mr Armstrong) dolls we had when we were kids. The wire will stretch in the area where the fuse wire is blown.

    https://www.wiringdepot.com/store/p/...All%20Products

    I did not ask the dealership, I am sure they have the right color (white).
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    Installed a brand new switch and now the only thing I have is headlights... everything else is dead?
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  13. #13
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    Quote Originally Posted by viperguy69 View Post
    Installed a brand new switch and now the only thing I have is headlights... everything else is dead?
    WTF! New Bad Switch?

    Now I'm not good with Electrics but Im wondering, can you put power down each wire (without using the switch to check you do not have any internal wire breaks?

    Wondering if the removal /disturbance of the light switch has fractured the wiring?

    Can the new switch terminals be tested to make sure its configured correctly?

    Bad earth from the switch?

    What happens if you put the old switch back? Do you get all the functions you had before?
    Last edited by Fatboy 18; 04-07-2020 at 02:26 PM.

  14. #14
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    Alright, taken everything back apart and got a little arc which resulted in a blown fuse. Now, I replaced that 20A fuse and everything seems to be working again; makes no sense why I only had headlamps before the arc and then the fuse blew. So, I pulled all the fuses this evening and re-seated all of them again just to be sure there are no weird connections in the fuse box.

    However, the switch gets very hot to the touch from time-to-time which gives me concern on the longevity of both the switch and possibly even the plug going to the switch.

    Continuing to work on and through this issue, anyone have a spell to get rid of GEN I gremlins?
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  15. #15
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    Today is all about the Brakes. The pedal is super stiff when braking and the fluid is very brown, assuming it has collected some moisture over the years.
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  16. #16
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    Given the stated lack of attention to the brakes by prior owner(s) as stated above, I would suggest that you check, clean clutch fluid reservoir...then bleed system thoroughly and HOPE you have saved slave and master cylinders.
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  17. #17
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    Quote Originally Posted by Steve-Indy View Post
    Given the stated lack of attention to the brakes by prior owner(s) as stated above, I would suggest that you check, clean clutch fluid reservoir...then bleed system thoroughly and HOPE you have saved slave and master cylinders.
    Yes, was looking at doing the clutch fluid as well, need to find a thread on that one as I am sure its a little different then the GEN V.
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  18. #18
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    Yes, as there is no bleeder on the Gen V which shares the fluid reservoir with the brakes. The clutch bleed procedure is the same for Gens I-IV...though most folks have historically skipped the bleed as it is a bit of a pain to a newbie. I think that you will find it pretty straightforward.
    Last edited by Steve-Indy; 04-09-2020 at 11:14 AM.
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  19. #19
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    If your light switch is getting hot, that is likely down to corrosion on the wiring or terminals.


 

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