Electrical Gremlin, 03 - Taurus Car Club of America : Ford Taurus Forum

FLEXCELL · 11-19-2012, 11:52 AM

After a heater core replacement, car will stall when headlight switch is turned on. Instrument panel lights will quickly light and immediately go out. I can only figure somehow a wire has been pinched after the dash removal and re-install or something has been shorted out in the instrument cluster. Any ideas, or solutions would be greatly appreciated...I've have the cluster out twice now and can't see anything obvious or wires that appear to be compromised. All other electrical works, only the cluster and trim lights...i.e. steering wheel button lights, radio lights, a/c lights
This is on an 03 Sable with the Vulcan...

kipper667 · 11-19-2012, 12:37 PM

Had the same thing happen to me on a Z24 & it was a pinched wire. If you did the heater core install yourself I would loosen the dash again & pull it out just a bit & then try the lights again. If all is well then you know a wire is pinched in between the dash & its mount. Wiring is pretty straight forward, wires from the switch lead into a bundle that goes towards the firewall. You should be able to loosen the dash, pull it back a few inches & reach under & CAREFULLY pull the wires down. Now, I'm speaking from experience with a different car but I'm sure someone else here can elaborate on my suggestion or give you a better one soon.

the_intimidator_02 · 11-19-2012, 01:47 PM

Not sure where or how in the dash the harness it routed, but you will have to go back and unfortunately follow the harness and loosen the dash where it's pinched if you can access it. If you had the dash completely out you may have to remove or completely take everything apart like you were replacing the heater core again. The wire could be pinched anywhere.

FLEXCELL · 11-19-2012, 08:58 PM

After further review, while running the cluster lights will flicker about every 3 seconds. Any other ideas before the painstaking job of removing the dash again?

FLEXCELL · 11-24-2012, 10:08 AM

Ok, I've tracked it down to a couple wires blue/white and the brown. These are parking lamps and 12v power source in the headlight and dimmer switches. Does anyone know where I can find an electrical wiring harness diagram as to where these wires start or end?

Breeves002 · 11-24-2012, 10:29 AM

I can find a pic of the harness maybe, but probably won't help. Let me know if you need anything else. Looks like the power is sent from the CJB, then the data wires go everywhere else!

Headlamps switch:

Parking Lights:

Connector view for the dimmer switch:

Connecter view for the headlamps/foglamp switch:

11-19-2012, 11:52 AM	#1 (permalink)
FLEXCELL Junior Member Member Number: 21127 Join Date: Jul 2009 Drives: 03 Sable GS 3.0L Vulcan Visit: My Garage Posts: 3 Trader Score: 0 reviews Rep Power: 0	Electrical Gremlin, 03 After a heater core replacement, car will stall when headlight switch is turned on. Instrument panel lights will quickly light and immediately go out. I can only figure somehow a wire has been pinched after the dash removal and re-install or something has been shorted out in the instrument cluster. Any ideas, or solutions would be greatly appreciated...I've have the cluster out twice now and can't see anything obvious or wires that appear to be compromised. All other electrical works, only the cluster and trim lights...i.e. steering wheel button lights, radio lights, a/c lights This is on an 03 Sable with the Vulcan... Last edited by FLEXCELL; 11-19-2012 at 11:58 AM. Reason: wasnt finished typing...accidentally hit enter button

11-19-2012, 01:47 PM	#3 (permalink)
the_intimidator_02 Crazy Devoted Member Member Number: 5295 Join Date: May 2005 Location: Miramichi, New Brunswick Drives: 2005 Taurus SE 3.0L Vulcan Bought with 111,432KM in October of 2012 Visit: My Garage Posts: 5,438 Trader Score: 0 reviews Rep Power: 16	Not sure where or how in the dash the harness it routed, but you will have to go back and unfortunately follow the harness and loosen the dash where it's pinched if you can access it. If you had the dash completely out you may have to remove or completely take everything apart like you were replacing the heater core again. The wire could be pinched anywhere. __________________ Life is a hard teacher, it gives you the test before it teaches you the lesson. The Human race is governed by it's own imagination. Please don't steal, the government can't stand the competition.

11-24-2012, 10:29 AM	#6 (permalink)
Breeves002 The Big Cheese Member Number: 49890 Join Date: Sep 2012 Location: St. Louis, MO Chapter: Midwest Drives: 2008 Mercury Sable Premier Visit: My Garage Posts: 4,199 Trader Score: 6 reviews Rep Power: 10	I can find a pic of the harness maybe, but probably won't help. Let me know if you need anything else. Looks like the power is sent from the CJB, then the data wires go everywhere else! Headlamps switch: Parking Lights: Connector view for the dimmer switch: Connecter view for the headlamps/foglamp switch: __________________ Sam 2008 Mercury Sable Premier 2012 Kia Soul Base AT 1.6GDI Moved On: 2000 Sable LS Premium Duratec View what I have for sale: HERE *http://www.taurusclub.com/forum/80-c...car-month.html* Last edited by Breeves002; 11-24-2012 at 10:45 AM.

11-19-2012, 12:37 PM	#2 (permalink)
kipper667 Junior Member Member Number: 51197 Join Date: Nov 2012 Chapter: Northeast Drives: 98 Taurus 3.0L Visit: My Garage Posts: 10 Trader Score: 0 reviews Rep Power: 0	Had the same thing happen to me on a Z24 & it was a pinched wire. If you did the heater core install yourself I would loosen the dash again & pull it out just a bit & then try the lights again. If all is well then you know a wire is pinched in between the dash & its mount. Wiring is pretty straight forward, wires from the switch lead into a bundle that goes towards the firewall. You should be able to loosen the dash, pull it back a few inches & reach under & CAREFULLY pull the wires down. Now, I'm speaking from experience with a different car but I'm sure someone else here can elaborate on my suggestion or give you a better one soon.

11-19-2012, 08:58 PM	#4 (permalink)
FLEXCELL Junior Member Member Number: 21127 Join Date: Jul 2009 Drives: 03 Sable GS 3.0L Vulcan Visit: My Garage Posts: 3 Trader Score: 0 reviews Rep Power: 0	After further review, while running the cluster lights will flicker about every 3 seconds. Any other ideas before the painstaking job of removing the dash again?

11-24-2012, 10:08 AM	#5 (permalink)
FLEXCELL Junior Member Member Number: 21127 Join Date: Jul 2009 Drives: 03 Sable GS 3.0L Vulcan Visit: My Garage Posts: 3 Trader Score: 0 reviews Rep Power: 0	Ok, I've tracked it down to a couple wires blue/white and the brown. These are parking lamps and 12v power source in the headlight and dimmer switches. Does anyone know where I can find an electrical wiring harness diagram as to where these wires start or end?

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