Only getting 5 volts on passenger side headlights. Topic is solved

[manovlov]

EDIT: Sorry today at work was a lot and i re read the post and here are the measurements you guys requested
1. 12.49V
2. 5.06V
3. 37mV
4. 5V

Put it back together. Turn on the headlights.
Black lead back on battery. Measure voltage each side of Fuses F21 & F22 under the hood. Four measurements in total.
Swap fuses F21 & F22 see if the problem moves to the other side.

Possible sources:
1. Bad connection, Current limiting resistors or Relay contacts in the Central Electrical Unit.
2. The common ground at the headlight connector has a high resistance to ground.

I would have a look to the relay.

[RickHaleParker]

I would have a look to the relay.

No commonality between High & Low that would not effect the other side also.
The ground on the headlight socket is my prime suspect at this time.

[manovlov]

I would have a look to the relay.

No commonality between High & Low that would not effect the other side also.
The ground on the headlight socket is my prime suspect at this time.

You're right.

[Luke.T5R]

okay, so on both sides of fuse 21 i get 11.75V. on fuse 22 i get 11.80 both sides. swapping the fuses changes nothing

[RickHaleParker]

okay, so on both sides of fuse 21 i get 11.75V. on fuse 22 i get 11.80 both sides. swapping the fuses changes nothing

Headlight socket ground is the only thing it could be in theory unless we are missing something.
The headlight socket ground would effect both the High & Low beam on one side only.

Some of the measurements don't make sense. If he getting 11.75V at fuse 22 he should be getting the same at the headlight connector. Measurement error?

Hook the black lead back up to the battery (-) .
Put Headlights on high beam.
Then take three measurements at the Headlight socket with the red lead. ( High, Low and Ground )
Take the three measurements twice. With the headlight connected and without the headlight connected.

[Luke.T5R]

i opened up the housing to take some measurements, but i started rolling the wire around in my hands and the insulation starts breaking off. obviously im going to replace this stuff and i will be back with you guys.

[scot850]

The internal wiring harness in the headlights go brittle and then the coating of the wires flakes off as you have now found. Sorry, should have mentioned this but I thought you had already been in there.

Neil.

[Luke.T5R]

Not your guys' fault I was in there just didn't inspect closely enough, The damage you see i did with my fingers very easily. I'm sure there is more damage where I cant see. Gonna get in there and have a look.

[Luke.T5R]

Okay guys, this is one of those where I was an idiot. I should have noticed the fact the plug showed 5vs. good news is the wiring for the ac pressure switch is working perfectly, bad news is if youve had one too many natty lights you can swap those plugs. When I put them in the proper place both systems worked perfectly

Moral of this story, headlight plugs=gray, AC plug=Black. Thanks for the help everyone, dont rip me too hard for this one..

[scot850]

Well done anyway. We have all had that moment (some cases many more than once!). It is unfortunate that the physical shape allows them to be swapped over in the first place. Glad you got is sorted.

Neil.