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  1. #1
    saturnspeed_12's Avatar
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    Fuse panel interchange (headlight issue)

    First and foremost, do any other year s-series engine bay fuse box interchange with the 95? I see the later years look very similar but wasn't sure if they were set up the same (under panel wiring and fuse/relay pins). I tore the track board off so the copper wires can't go back in unless I want to spend hours drawing a schematic.

    I have been tracing an issue with my headlights being dim. Driveable, but not as bright as they should be. I noticed a decent drop in voltage from direct battery voltage to bulb connector. I saw Bill had similar issues and he had corrosion in the fuse panel, so I tore mine open. Found and cleaned corrosion, and low beams didn't work. That's when I tore the whole damn thing apart and realized the mistake I made, but no corrosion was inside the actual panel.



    EDIT: Also does anybody have the wiring schematic for the headlights? I need to trace the whole system.
    Last edited by saturnspeed_12; 09-13-2015 at 06:43 PM.
    Ian---The Fat Ass

    1995 SL2-High compression engine FOR SALE
    2010 Chevy Cobalt SS- tuned with plenty of goodness
    2002 SC2-New daily
    2017 Kawasaki Ninja 650 KRT- got a stupid deal
    2003 Ford Taurus SES- free daily beater

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    rubensw2's Avatar
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    Last edited by rubensw2; 09-13-2015 at 08:59 PM.
    Buy it, Build it, Drive it, Break it, Fix it

  3. #3
    saturnspeed_12's Avatar
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    I believe I already found my answer. 91-94 appeared to be completely different. 96-on seem similar but appears to be pinned differently. SO I guess I am stuck rebuilding this one. Really didn't want to since I will have to tin stranded wire to keep it rigid. I could order 20awg primary wire, but I care not to wait for it if I am doing this.
    Ian---The Fat Ass

    1995 SL2-High compression engine FOR SALE
    2010 Chevy Cobalt SS- tuned with plenty of goodness
    2002 SC2-New daily
    2017 Kawasaki Ninja 650 KRT- got a stupid deal
    2003 Ford Taurus SES- free daily beater

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    6S Staff redhotFTW!'s Avatar
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    All the yards around and you can't find a 95?
    Black 2006 Cobalt SS/SC
    ZZP | GMPP |EBC |GM Stg2

  6. #5
    saturnspeed_12's Avatar
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    I've found some but most are over 100 miles away. The closest is 50-60 miles away. The problem is, I work 6 days a week and if I get a Saturday off, most yards aren't open. And the closest one with it wants $70. Bit ridiculous to me
    Ian---The Fat Ass

    1995 SL2-High compression engine FOR SALE
    2010 Chevy Cobalt SS- tuned with plenty of goodness
    2002 SC2-New daily
    2017 Kawasaki Ninja 650 KRT- got a stupid deal
    2003 Ford Taurus SES- free daily beater

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  8. #6
    Modding_out's Avatar
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    Fuse panel interchange (headlight issue)

    I was called but ur answer was already found

    Edit: one of my books might have the head light schematics. I'll check

  9. #7

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    car-part.com. 25 bucks from a junkyard in Amboy, IN. Not sure how much they charge for shipping, though.

    Rays Auto Parts. Looks like if you ask for the fuse box for an SL it's 25, if you ask for an SC or SW, it's $30.

  10. #8
    6S Moderator S.Bretz's Avatar
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    I have a 95 body/electrical service manual. Let me know what you need and I can take picture and upload them.
    -6S Resident Mechanical Forensics member #001.
    1995 SC2 Turbo 3.6L DOHC, 6sp manual, Ford 8.8 rearend running on MS3x.
    1998 F-250 5.4L triton...stock.

  11. #9
    saturnspeed_12's Avatar
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    Anything associated with the headlights. I need to trace every wire all the way to the grounds. The voltage drop has me puzzled, so I'm going to trace the wires to every junction to find the drop and check grounds.
    Ian---The Fat Ass

    1995 SL2-High compression engine FOR SALE
    2010 Chevy Cobalt SS- tuned with plenty of goodness
    2002 SC2-New daily
    2017 Kawasaki Ninja 650 KRT- got a stupid deal
    2003 Ford Taurus SES- free daily beater

  12. #10
    siris's Avatar
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    It's pretty common with the old Mopar's I fuck with to run a new battery fed power feed to the headlights via stand alone fuse holder and a relay, driven by the stock headlight wiring.

    Does wonders, might be easier than trying to diagnose what's going on with yours.
    72 Charger: pissed me off, on jackstands.
    95 SW1m: Dohc swap. DD. I can haz boost?

  13. #11
    Approved Vendor ZombieSatty's Avatar
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    That is common for the Samurai world too. I never liked that method, perfering to do the work and find and fix the problem.
    It's not my fault, blame the radiation.

  14. #12
    siris's Avatar
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    Quote Originally Posted by ZombieSatty View Post
    That is common for the Samurai world too. I never liked that method, perfering to do the work and find and fix the problem.
    Meh, just depends on the level of commitment to the car. I personally feel safer with a 20amp load on new wire than old wire.
    72 Charger: pissed me off, on jackstands.
    95 SW1m: Dohc swap. DD. I can haz boost?

  15. #13
    6S Moderator S.Bretz's Avatar
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    I would suspect that the wires are starting to get a little corroded inside the insulation. When I re did my wires I stripped out a lot more than I would have liked just to get back to a place in the original wire where it was still all nice a copper. If you strip the wire the outer copper strands are black you need to keep cutting back a few inches until you find clean copper.

    I'll go take some pictures. I'm assuming its the SL2 in your signature and avatar?
    -6S Resident Mechanical Forensics member #001.
    1995 SC2 Turbo 3.6L DOHC, 6sp manual, Ford 8.8 rearend running on MS3x.
    1998 F-250 5.4L triton...stock.

  16. #14
    6S Moderator S.Bretz's Avatar
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    If you click on the pictures in the storage gallery there get pretty large. I dumped them in the public gallery.







    -6S Resident Mechanical Forensics member #001.
    1995 SC2 Turbo 3.6L DOHC, 6sp manual, Ford 8.8 rearend running on MS3x.
    1998 F-250 5.4L triton...stock.

  17. #15
    saturnspeed_12's Avatar
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    Thanks Sam. I went to check grounds when I found why my low beams weren't working. Damn pins in the connector at both headlights was too loose. Amazing how random that could happen all of the sudden. Bent tabs back and lights work again. But not sure if my brightness is back. Voltage wise, I'm losing .1 volt from input at fuse panel to headlight connector, so it appears good. Guess shall see if night driving is improved.
    Ian---The Fat Ass

    1995 SL2-High compression engine FOR SALE
    2010 Chevy Cobalt SS- tuned with plenty of goodness
    2002 SC2-New daily
    2017 Kawasaki Ninja 650 KRT- got a stupid deal
    2003 Ford Taurus SES- free daily beater

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