LUVTruck.com

Hello,

I have a 1977 Series 6 Luv. She runs great but I have been dealing with some electrical issues that I just can’t quite figure out.

It started with the headlights going out intermittently. I would be driving at night, and after 5-15 minutes of driving, the frontmost fuse in the fusebox would blow. I would replace the fuse, and drive the rest of the way home, and the lights would not turn off again.

What I have done already:
I visually inspected all the wires, terminals and the lighting switch. I cleaned off the battery terminals and ensured proper connection. I made sure that all the fuses in the fuse box corresponded with the factory specifications. The plastic around the metal clip that retains the frontmost fuse was a bit melted. I turned the lights on, and that fuse got hot almost instantly and started melting a flux looking material onto the plastic. The fuse didn’t blow, but the wire, the fuse, and the clips were all a lot hotter than the others.

I replaced the headlamp switch a few years ago, so I don’t think it would be that, but could a faulty switch cause this problem? Should I bypass the existing wires? and/or replace the entire fusebox? Any other suggestions on possible solutions?

Thanks so much,

anytime you have electrical gremlins in a LUV first do the fuse box fix and then go from there. Do a search. There are a couple of ways to approach it. It often solves the problems.

If you get in to bad wires and you decide to re-wire the headlights, Try a headlight relay. It will take the amperage off of the fuse box let it operate cooler and not melt the plastic housing. I've seen plenty of LUV fuse boxes that have been melted badly enough to cause the terminals inside to become loose and not produce a good contact to the fuse itself. You may have a bad ground--intermittent or otherwise.

We get a lot of people that come here and claim the stock wiring is junk on these trucks. Truth be told Manu of us run the stock systems with zero problems. I modified mine to work with my small block and had never had to do any repairs since. Before saying you want to replace all my f it (not saying you said that but many do) do the fuse block repair that was mentioned above. If after that you have issues get back to us and we will try to help you out. When everything is clean these electrical systems usually work great.

Here is a link to the fuse box clean up article

http://www.luvtruck.com/pdf/Fuse_Box_Repair.pdf

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Certified pilots, looking down on people since 1903.

idk if you meant the headlight switch on the dash or the turn signal switch, which is also your dimmer switch on the steering column, I am on my third dimmer switch and it always caused my headlights to quit so that might be something to look at too

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1980 4x4 LUV, 3 inch body lift, 4.56 gears, 31x12.50r15 Super Swamper IROKs, Weber Carb, Electronic distributor,