Low/High beam inop

[TheDurk]

Sweet, I may just de-pin those two wires from the plug and jump them that way.

That would be fine. Then you can reverse it if you get a new cluster. Let me know if it works. This is the second or third fail of that cluster auto-off module we have seen on here. As I said, it's probably a burnt PCB trace. You may be able to find it working out from plug C27 if you break down the cluster. Or there may be a failed mini-relay on the board. I have never seen any good diagrams of the inside of the combination switch, so you are on your own.

 

[Twan]

That would be fine. Then you can reverse it if you get a new cluster. Let me know if it works. This is the second or third fail of that cluster auto-off module we have seen on here. As I said, it's probably a burnt PCB trace. You may be able to find it working out from plug C27 if you break down the cluster. Or there may be a failed mini-relay on the board. I have never seen any good diagrams of the inside of the combination switch, so you are on your own.

I'm going to give it a try tomorrow, and I'll let you know how it worked out. The Toyota specialist I took it to hadn't seen this problem before, and the speedometer repair shop I called hadn't heard of anything like it. Even the Toyota factory repair manuals didn't delve into the auto-headlight board.

 

[Twan]

Pulled the cluster, didn't have any luck getting the pins out, so I ended up snipping the wires and crimped some connectors on so I can connect them back to normal if need be. I can now turn the lights on and off with the headlight switch. With my typical luck with this thing, it would appear when I got it back from the mechanic, the high beams were stuck on. Still no low beams, just highs all the time. Not sure what I'm going to do about that, but I may just swing by the mechanic shop in the morning.

 

[TheDurk]

Pulled the cluster, didn't have any luck getting the pins out, so I ended up snipping the wires and crimped some connectors on so I can connect them back to normal if need be. I can now turn the lights on and off with the headlight switch. With my typical luck with this thing, it would appear when I got it back from the mechanic, the high beams were stuck on. Still no low beams, just highs all the time. Not sure what I'm going to do about that, but I may just swing by the mechanic shop in the morning.

That's curious, because the dimmer relay normal position is LOW beams. So either the stalk switch is sending the ground signal out the Violet wire on Pin 7, even in the low position, or the relay is stuck, and not opening when there is no ground to the dimmer relay coil at the yellow/blackwire on Pin 3, or the Main DRL relay has had a cerebral hemorrhage. Or there is a short somewhere. See if there is ground on that wire on Pin 3 of the dimmer relay with stalk in LOW. (There should not be.)

With those two checks, I can tell you what to do next.

 

[Twan]

I'll have to get in there and take a peek in a day or two, as today has decided to be 32° and snowing.

 

[TheDurk]

I'll have to get in there and take a peek in a day or two, as today has decided to be 32° and snowing.

Yikes! 80 degrees in NJ...

 

[Twan]

Well, the shop took another look at it, and we both came to the conclusion to just say screw it and stop trying to fix it. I already have a projector retrofit kit sitting at home, which includes the relay harness. My hope is to be able to bypass a majority of the circuit and be able to intercept signals somewhere near the switch. [MENTION=10169]TheDurk[/MENTION] I hate to ask for more input, but do you think this is possible? Ideally, everything would function as normal with the switch, but I could just intercept the low/high beam signals and trigger the relay with them.

 

[TheDurk]

Well, the shop took another look at it, and we both came to the conclusion to just say screw it and stop trying to fix it. I already have a projector retrofit kit sitting at home, which includes the relay harness. My hope is to be able to bypass a majority of the circuit and be able to intercept signals somewhere near the switch. [MENTION=10169]TheDurk[/MENTION] I hate to ask for more input, but do you think this is possible? Ideally, everything would function as normal with the switch, but I could just intercept the low/high beam signals and trigger the relay with them.

Well, everything except the auto-off, sure. However, if the high/low defect is in the stalk, then you won't be able operate the high/low from the stalk. If you have ruled out the stalk, then easy peasy.

I bet I could fix it....

 

[Twan]

Well, everything except the auto-off, sure. However, if the high/low defect is in the stalk, then you won't be able operate the high/low from the stalk. If you have ruled out the stalk, then easy peasy.

I bet I could fix it....

Hah, glad to see the enthusiasm. Stalk was replaced back when we first started this journey. Auto-off is of no concern now since I'm not going to want that once the ballasts are hooked up. Primary concern is on/off and low/high via the stalk.

 

[redneckj]

headlights

I am having EXACTLY the same issue with my 2001 4runner. My toyota mechanic has been scratching his head not getting anywhere with my issue. I am going to print out what you did to bypass your auto off feature and see if we can get my headlights going soon.

 

[TheDurk]

I am having EXACTLY the same issue with my 2001 4runner. My toyota mechanic has been scratching his head not getting anywhere with my issue. I am going to print out what you did to bypass your auto off feature and see if we can get my headlights going soon.

You're lucky, those instructions will work fine with a 2001. In general never expect wire colors and pin-outs to work across years. They changed a LOT.

 

[redneckj]

You're lucky, those instructions will work fine with a 2001. In general never expect wire colors and pin-outs to work across years. They changed a LOT.

The wires going to the cluster were bridged today. Guess What? I HAVE HEADLIGHTS NOW!!!

What a cluster F7cK trying to figure out the problem. I just ran across this thread last night and BINGO now I have lights. Every tech I talked to said it was the combination switch. NOPE, it wasnt. Some of my good friends work at Tacoma Speedometer and they do cluster repairs. I though about taking it to them but I will just have to remember to turn off my headlights. I did before anyways so no big deal.

I think it is weird for Toyota to have put the auto off feature in the cluster. Over engineered. Oh well. 274,000 miles and this is the first thing that I have ever had a problem with. Pretty good track record. I will just keep on driving till it falls apart.

 

[Twan]

Found a local place that does odometer programming, so a new(used) cluster has been ordered. Now to see if that'll fix it.

 

[Twan]

Replaced the instrument cluster with a new one, no change from before. About ready to roll this into the street and light it on fire.

Current situation: Low beams still inop. High beams come on and stay on as DRLs. Pulling the stalk with the headlights off will flash high beams, with headlights on does nothing. Replaced the instrument cluster and turn signal/headlight stalk. DRL module swapped with known good and no change. About to take it back to the mechanic again since I've already bugged [MENTION=10169]TheDurk[/MENTION] enough.

 

[TheDurk]

Replaced the instrument cluster with a new one, no change from before. About ready to roll this into the street and light it on fire.

Current situation: Low beams still inop. High beams come on and stay on as DRLs. Pulling the stalk with the headlights off will flash high beams, with headlights on does nothing. Replaced the instrument cluster and turn signal/headlight stalk. DRL module swapped with known good and no change. About to take it back to the mechanic again since I've already bugged [MENTION=10169]TheDurk[/MENTION] enough.

Why did you replace the cluster if you weren't going to use the auto-off? Or did you give up on the projectors?

I gave you some tests to do to isolate the high/low problem. I really can't be any good to you without those answers. I like to troubleshoot, not guess.

 

[Twan]

Why did you replace the cluster if you weren't going to use the auto-off? Or did you give up on the projectors?

I gave you some tests to do to isolate the high/low problem. I really can't be any good to you without those answers. I like to troubleshoot, not guess.

Projectors are still in the cards. Used cluster was relatively cheap, so I figured I'd try and get it back to working stock condition before trying something else. I do have 10 days off starting on Saturday where I can really get in there and test/probe.

 

[Twan]

Saga continues... According to the guy I'm paying to track this down, there appears to be some fried diodes in the Main DRL Relay down by the brake pedal. He tracked down a used one and was waiting for it to be delivered.

What he figured out after I initially dropped it off with him was that most everything was acting normal in the circuit, but somehow somewhere the low beam signal was feeding to the high beam wire. Nearly everything was acting as it should, the switch was sending out the proper signals and all that, and the new cluster had no issues. Just so happens that when they were diagnosing it the first time, something happened that caused the high beams to stick on. Not at all surprised by any of it with my luck with this thing.

 

[Twan]

To put this thread to rest finally, everything now works as it should. Initial fault in the auto-off circuit was fixed with the gauge cluster replacement. High beams being stuck on was fixed with replacing the Main DRL Relay under the steering column. I even learned that the non-broken fog light still actually works.

I appreciate the past help [MENTION=10169]TheDurk[/MENTION]

 

[Gymoutlaw]

New here...2000 limited with very similar problem. I have NO heads or rear lights. Check all fuses and relays. The only lights I can get is to pull back on the stalk for high beams. I took the cap off the red relay in the fuse panel under the hood and manually made relay contact. Lights came right on ??
Any clues?? I was replacing bulbs in cluster with leds. I assume they should still work with cluster out correct?

 

[TheDurk]

New here...2000 limited with very similar problem. I have NO heads or rear lights. Check all fuses and relays. The only lights I can get is to pull back on the stalk for high beams. I took the cap off the red relay in the fuse panel under the hood and manually made relay contact. Lights came right on ??
Any clues?? I was replacing bulbs in cluster with leds. I assume they should still work with cluster out correct?[/QUOTE]

No, it won't. The auto-off function goes through the cluster so it needs to be in the circuit.