Headlights staying on/ Relay part vw 911 941 583 6 spade

Whilst out last Saturday at the workshop my headlights came on on there own, no key in ignition and the headlight switch was off, Blue main beam light in dash clock was on, fiddled about with the Relay under the fuse box and the front right wire was very hot, wiggled the Relay and lights went out but when operated the main beam on the indicator stalk headlights and main beam came on again even when switched off,,,There appears to be 6 yes 6 terminals on my relay and i can only find relays with 5 terminals and i have sourced a spare light switch with dimmer control as was told this could be the problem, in the meantime i have disconnected the wire that was hot from the Relay and taped it up however i now have no headlights that work.

Who knows,any ideas ?? my bus is a 66.



Thanks

Ron

Sounds like a short or possibly one of the components relay etc are faulty . . .

Thanks Daz

Thought it could be the headlight switch shorting out so will remove and clean it, also any ideas on the terminals on the relay, as you have a 66 thought you may know, pretty sure its the original relay, and what is actually wired into the relay,,Headlights, mainbeam, ?????? cant find nothing in my book reference the relay.



Ta mate

Ron

Ours doesn't have the relay, it works of the floor switch like the earlier models . . . the other thing would be to check the switch end as the terminals in there get really gunked up

Sorry Ron is yours a yank bus as that is the only one that seems to have the relay

http://www.thesamba.com/vw/archives/info/wiring/bus_66.jpg (non usa)

http://www.thesamba.com/vw/archives/info/wiring/bus_66_USA.jpg (usa)

The rest are on here http://www.thesamba.com/vw/archives/info/wiringt2.php looks like vintage bus site is no more . . .

Hi Daz

Bus came out the factory in American spec but ended up in France but when i dont know, thanks for the info, will do the switch 1st then perhaps faff around with the Relay,

Ta Bud



Ron

Hi Ron, didn't realise your bus was usa spec. like daz i dont have the benefit of relays on the headlight circuit just thick cables.I looked at the wiring diagrams but they don't seem to help much. Probably is the relay or possibly the indicator stalk switch or wiring. You may be able to to a temp fix and just have dipped beam. I guess you have hazard lights and a 9 pin relay system for thee indicators which can also cause problems. Owen

Hi Owen

Now you mention it i am really not sure without checking M plate details if my bus was Euro spec or USA, i do remember from the plate it left factory with US spec bumpers, will have to go find the Mplate details in my files and check it out.i am sure though that it has a 6 pin relay but the part number not visible until i can remove it from the bus.

Thanks

Ron

Ronnieboy59 wrote:Hi Owen

Now you mention it i am really not sure without checking M plate details if my bus was Euro spec or USA, i do remember from the plate it left factory with US spec bumpers, will have to go find the Mplate details in my files and check it out.i am sure though that it has a 6 pin relay but the part number not visible until i can remove it from the bus.

Thanks

Ron

Guessing it's relay J7 pins looks like they are 15, 30, KBI, 54, VR, VL, 49a, -S and 54F . . .

Had the relay out today and its part number is VW 311 941 583, It is a 6 spade relay and am searching everywhere for a replacement, any help appreciated. Or whats my alternative ???



Thanks

Ron

Is it a six volt relay? the five pin relay does the same job on later models so could probably made to work just need to regig the wiring abit and lose a wire. I rewired by indicators and hazards as the orginal wiring was complicated and used two relays and couldn't get it to work properly.

If you are still going to standford hall Peter Good may have a stand there and be able to help.

owen

Thanks Owen, my indicators are on a seperate relay so figuring out the wiring is my nightmare, off to Vicky farm in the morning, got to 5 spade relays to take with me so fingures crossed otherwise will just get pissed up and a good convoy Sunday.
Bus is Factory spec 1966 12 volt but whos to say add ons etc eh


Ta mate



Ron

Is this it, J7 High beam relay VW part number 311 941 583 A Bosch number 0 332 215 018.
(VW part number 111 941 583 can be used with modification).

Apparently late type 3 and bugs have the same type of relay with same
pins but different shape so if you cannot find a split one then that is
your other option.

Very similar relay Daz however the one i have fitted does not include the A at the end of the part number, after loads of rumaging in boxing all weekend did not find the exact type, will keep looking or will opt for a sparky to re-gig the wiring.


Lost my brake lights now also so the drive back home was interesting, no headlights and no brake lights, will check all my earths again.


Thanks

Ron

Headlights now sorted, but just to add info on issues i had, headlights staying on when lights switched off, Main beam not working when using indicator stalk, lost headlights and mainbeam all together, advice from many websites and friends were, Bad earth,,checked and all ok, poor connection to fuse box, checked and all ok, poor fuse terminal connection,,checked and all ok, finally went and took out the 6 terminal relay,, stripped it and Found the problem, it was full of rust as it faces upward toward safari windows, sourced a replacement 6 pin terminal relay which was from a 1970s volvo, slight change in the terminal connections but sorted the problem for now and works, only issue i have is when i use the indicator stalk to flash main beam it flashes headlights instead, if the wiring was longer i would have made this relay face downward but its not without adding extensions which i may do in the future. Just in time for MOT next week, however snapped the head of my replacement washer bottle today, any more obsticles will surely follow, but happy with myself that i am learning as i go.



Ron:)

Well done Ron they are made to test us I'm sure . . .

I am sure someone can lend you a cap for the MOT . . .

Thanks Daz, the washer bottle kneck snapped but have super glued it, ther cap is ok for now, wont fill it when MOT will just plead ignorence and say washer bottle is empty.

off to Devon Friday with work so taking camera just in case a few dubs out and about.



hope all well with you guys, and the new baby, yes its amazing how much extra space such little children require when travelling, a roof rack is good but seriously, a westy trailer would be awesome behind your bus, it really carries all you need, or lisas bus or both your buses,

Ta Daz and hope to catch up with you guys real soon.



Ron

well done Ron, glad to hear you are back on the road, might be worth to source another one of those relays just in case. Glad mines abit more basic.

Sorry can't help you with a washer bottle , never had one in the frist place and put an modern bottle on mine.

cheers owen