Date:         Mon, 29 Jun 1998 09:15:02 -0600
Reply-To:     Fred Porter <fporter@EYRING.COM>
Sender:       Vanagon Mailing List <Vanagon@vanagon.com>
From:         Fred Porter <fporter@EYRING.COM>
Organization: EYRING, Corp.
Subject:      100w H3 highbeams DO melt ignition switch!
Comments: To: vanagon@vanagon.com
Content-Type: text/plain; charset=us-ascii

kinda embarassing but true.....

Derek warned me/us about this possibility:
i replaced the 50w H3's in my high beams with 100w bulbs without
incorporating a load reduction relay.  i went out for a long evening of
fireroading with my highs on continuously and the next morning the
switch was malfunctioning.  white melted plastic had 'welded' the
ignition switch wiring harness to the ignition switch on the headlight
terminal wire.

i started the van by nicking the starter wire and the red power wire and
jumpering them with a chunck of coathanger, while turning/jiggling the
key to get power to the ECU.  once running (while on the way to NAPA to
buy a new switch) the engine cut out three times.  the first two were
while rolling down the hwy and i was able to jiggle the key and
reenergize the ecu ciruit (i think that's what it did) before loosing
more than 5mph.  the third time was at a stop light waiting for the
green.  embarrasing :)

BTW the bentley's terminology isn't entirely consitent/clear regarding
the replacement of the switch.  the first five times i read the
instructions, it seemed that i needed to remove the lock core (which
requires drilling) to remove the switch.  this isn't the case, just
remove the steering lock collar and loosen the set screw and it comes
out.

back to 50w bulbs till i put in relays!

later,
fred