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Automotive/95 mercury sable GS 3.0L

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Expert: - 2/3/2010


Question
Hello Ernie,my headlight switch keeps going out,and i was curious on what do you think i should look for as the problem?

Answer
A new headlight switch, perhaps?  Most likely!

Many Fords have made use of headlight switches with integral auto-reset circuit breakers, so one possible cause of your problem could be the cycling of an overly-warm thermal circuit breaker.  This tends to happen as the CB/switch combination ages, with the consequent result of its contact resistance going up due to oxidation, possibly dramatically due to pitting.  Increased contact resistance means more heat dissipated in the switch and/or CB, thereby increasing temperature rise to the point at which the CB begins a trip-reset-trip-etc cycle.

Standard fix:  replace the aging headlight/CB combination.

Better fix (which I used): engineer a relay interface using headlight contactors and appropriately-sized stand-alone CBs, and use the existing (but new would be better) headlight switch and dimmer control  to operate  these contactors which would , in turn, switch the headlights.  Such a system could have the added advantage of offering an upgraded and more direct run from the power bus to the headlights, offering less voltage drop and consequent better lighting and likely better life from the quartz-halogen lamps; QI lamps, unlike conventional incandescent lamps, can suffer shortened life in operated at less than rated voltage if this results in the quartz envelope not running sufficiently hot to prevent the sublimated products from the filament from condensing on the quartz glass.

This probably is more answer than you need or want, but the foregoing (properly engineered) does offer a significant improvement over OEM routed-through-switch systems.

Regards ... EGK

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Ernest (Ernie) Kenward

Expertise

The challenges I most enjoy are thoughtful technical questions of a trouble-shooting nature in both electrical, power electronic and mechanical systems, mainly automotive but also machine control and small-machine PLC applications. Please note, however, that I am NOT a walking shop manual! I DO, however, make it a point to have those manuals and other service literature for those vehicles I DO own, and highly recommend that anyone serious about maintenance or modification of their vehicles do the same; MOST of your answers WILL be found there. For that matter, I do NOT go out of my way to acquire shop manuals for any vehicle I do NOT own! That being the case, any general query to me along the lines of "What is the meaning of this code read from the ECU of my 2015 XYZ?" or "Where is the fuse for the windshield washer pump found?" (try your car's electrical distribution panel for a start!) will not go far. What I do offer is a pretty good collection of literature, insights and hands-on experience with 1950s to 1980's Ford products (plus a developing database of information and practice with the Mercedes diesel cars), along with an engineering perspective and the ability to design and implement custom control, electrical and mechanical subsystems for vehicles. For that reason, I am happy to make my thoughts and efforts available to those who are of like mind and/or are seriously making a point of learning about their vehicles. Use the Opportunity to Learn!

Experience

A key skill in my work and hobby pursuits both is STRATEGIC TROUBLESHOOTING. I am a senior instructor in Electrical Engineering Technology at a leading Canadian polytechnic, my areas being Electrical Power and Industrial Control, electrical and electronics design and manufacturing, and AutoCAD and related CAD/CAE software - plus equipment problem-solving and new equipment design and prototyping. Hobby-wise, I have 30-plus years of experience in auto restoration, mostly in electrical and mechanical systems. Ongoing projects include a 1959 Edsel Corsair, my 1978 Ford E250 class-B motorhome conversion, and the care and upkeep of my Mercedes 300CD. My vehicles become engineering test beds for electrical and mechanical upgrades as ideas present themselves. This includes the design and production of circuit boards to restore or enhance features for which no OEM replacement parts are obtainable, or where better specifications or reliability can be had via newer concepts. Regarding the E250 RV conversion, I designed and continue to revise a custom power distribution system, managed by a Programmable Controller (PLC); this has made most revisions as easy as uploading new firmware as I develop it. The "mini" PLC is a powerful device for custom automotive control systems. One good example (there are many) would be the Moeller "Easy Relay"; these offer a wealth of control, monitoring and variable-and-status display options for such projects. A good example project which has worked well is that one for my RV noted above, which has been on the job - revised in firmware only - for a decade now. It is a load management and charging control system to avoid the sulfation-induced early failure that often befalls deep-cycle batteries used in RV power applications. The battery installed in 2003 lasted long enough to more tnan pay for the PLC that contributed to its longer life ... and the PLC will be there for the next battery as well!

Organizations
IEEE - senior member ... past WCC Student Activities; SME - senior member ... past chair, greater Vancouver chapter chair 318; Edsel Owners' Club - have served in various capacities on chapter executive during seventies; have been Power and Driveline resource on the Edsel Owners' Club "E-team" for more than a decade.

Education/Credentials
Graduate of UBC

Awards and Honors
Certificates of appreciation from IEEE and SME for work in student and chapter activities

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