The plastic broke where that screw , screws into the headlight switch. Anyone come up with an easy fix? If anything , ill probably just stuff something up under the switch. Cut pool noodle? My electric fan mysterious just stopped working, after i changed my waterpump and thermostat housing. The fan still works direct to the battery. Im gonna do a little more testing.

 

This happened on my spare XJ when I took the switch out to go in mine

Now that a replacement has arrived from Rock Auto, I will do the following.

make a plastic "cup" that slips over the back of the plastic cylinder and glue it in place, then place a plastic disc "in the hole" and glue that to reinforce

It has to be thin, and accurately cut to allow the switch to be screwed in as it should, but strong enough to take some pressure,

Not totally easy or quick (its not my DD), but if you want it fixed properly (for DD use) this should work

Its hard to work on this area, access is poor, and no matter how many plastic trim parts you remove, the switch is caged in by the metal structure of the dash itself

 

Just let the switch and wiring hand under the dash.

 

That gets old pretty quick on a DD

In addition the harness is so short (on my spare XJ), that isnt really practical

made getting the switch disconnected from the pronged harness very annoying.

I will let youse know how I go with my repair.

The ideal is a section of cutoff plastic tubing that is a near perfect fit

cause its my spare XJ and i am busy, may take me a while to get around to, but I really like keeping my spare 100% functional, makes life so much easier to keep mine on the road

Its been giving me quite a lot of auto electrical grief recently. Probably enough for most people to give up on it (if you were paying for someone else to fix it)

I swear at least 10% of folk are driving around with at least one light out on their vehicle at any one time

 

At the PDC take the fan relay out and with key ON, jump pinsocket 30 and 87. If that works, you know the issue is upstream from the switch side of the relay because downstream everything works.
If not, we can go diagnose from there

 

At the PDC take the fan relay out and with key ON, jump pinsocket 30 and 87. If that works, you know the issue is upstream from the switch side of the relay because downstream everything works.
If not, we can go diagnose from there. The fan circuit is relatively easy.

 

I'll have to check that out with the fan. thanx. Headlight switch im gonna do some ziptieing.

 

I did the 30 / 87 jump and nothing. The fuses are good, the relay is good, its showing 74 ohms. It's clicking like it should. I connected the 2 wires where the switch would be, and something clicked, and the fan just moves a hair. Now ill mention the previous owner, has the switch on wire pushed into the stock aux fan relay socket in the under hood box. It's pushed in the far left socket number 86. With the relay pushed in. It worked before i did the water pump and the housing. The offside on the switch is right to the battery. The middle socket' number 87 doesn't have any connection in the box . Maybe ill get a new relay too.

 

Headlight switch is ziptied, works until the zipties break.

 

The wire that was shoved into the relay, my stepson said, lets touch that wire to a ground and flip the switch on and it worked. Have all the connectors and new wire,
except i need a bigger loop connector for the battery bolt. New switches too.