GC2400 rear combo lamps/blinker issue

[Dmacleo]

this is odd, noticed last night when headlamps on my rear combos are not on.
when blinker/4way activated the flasher is clicking but the dash arrows/4way switch not lit AND the actual lights themselves are not blinking.
all other dash components work.
no power to the actual lights confirmed and all fuses are good.
have not had much time to look into and will be day or so before I can, but was wondering if anyone had seen this particular scenario before so that when I get chance to actually look I'd have a possible starting point.

 

[MoMower]

Switch gone bad?

 

[Dmacleo]

possible don't think so, turned out the combo lights do work (was still light out when I looked) only the blinkers and 4 ways don't.
flasher is working but no dash arrows light (rest of dash lights work) and no rear blinker work so BOTH switches are passing signals to the flasher unit.
think I need to look schematic and check ground paths off flasher unit.
just had not had chance yet.

 

[kenmbz]

First try cleaning off ground connections and tighten. Any gunk on these will cause problems.
Then check to see if you have voltage coming from blinker if you are comfortable with a Voltmeter.

 

[Dmacleo]

yeah I did cleaning of harnesses in area no joy. going to first check the dash blinker light traces to see if voltage both sides if not (especially if ground side) I have a start point.

 

[Dmacleo]

yeah got no voltage on either side at dash lamps or turn signals.
attached is schematic and relay layout. got to study it to find where a common fail could be.
got lower cowl pulled away as I need to swap out tach cable due to sticking in cold weather anyway so I'll look at this. not gonna spend money though, 4way flasher alone is 110$

 

[kenmbz]

Since it's two relays, I would pull the fuses and check for continuity. Feed to contacts of relay or grounds from relays.

 

[Dmacleo]

fuses are all good did check that first thing.
I am really thinking ground path after relays as if ground itself bad AT relays none would click which all 3 do.
its actually 3 relays, one for each blinker side and one for 4 way. something common on the outgoing path of all 3 has to be involved.

 

[kenmbz]

Maybe they put a ground out by where the lights connect?

 

[Dmacleo]

there is connector but I can't see how that would affect the dash signals, best I can tell that connector only for the rear lights. after tach cable done gonna pull that connector and clean to be safe but really think its something in wire LOOM going to the 3 relays. and its a tight invisible spot to work on

 

[kenmbz]

Good luck, was hoping maybe a ground closer to lights to make the fix easier. Would be something common, so would still be surprised if a broken wire, but stuff happens.

 

[Dmacleo]

well except for tie wraps tach cable is replaced. 4 holes in it where it routes under left footwell. no way that would cause issues in winter LOL
gonna insulate with fuel hose and tie wrap it then start probing connectors on the 3 relays I guess.

 

[Dmacleo]

Yup one broken wire inside connector to flasher unit. Tomorrow I'll try to unpin the contact push out and solder it but it's tiny and pretty rotted. May have to just flatten a wire solder end to create a contact point and super glue the wire to connector.

 

[Dmacleo]

just in case someone else sees this issue this is how it works.

when you turn on left blinker switch relay 1 in pic is activated sends signal to flasher relay item 3.
for right blinker its relay 2 activated signal again to flasher relay item 3.

few scenarios.
when you turn on left OR right blinker and either dash is out or actual blinker is out (one works other don't) check bulbs.
if both are out BUT flasher unit is NOT clicking AND 4 ways work check the applicable relay for direction first and its output to flasher relay item 3.
if both are out BUT flasher unit IS clicking AND 4 ways work check outputs from flasher unit.
if blinkers work BUT 4 ways don't go direct to flasher unit test power in from switch and outputs.

My issue, dash AND actual blinkers did NOT work but flasher was clicking when 4 way activated AND either left/right activated so then go right to flasher unit. my problem is the wire in number 2 slot on top of connector (latch side) is a positive input from battery, it provides the power out to ALL items from flasher. luckily it was second wire I checked so I found it fast.

edit: of course the org pin disintegrated as soon as I touched iron to it. had no female connectors that size so trimmed a long male spade to fit in connector housing, bend it so always contacting relay pin, little super glue on wire as I slid in housing and on hole where wire comes out to hold in place. cycled plug in and out 4 times works fine and plug latches in place.
called it good.

 

[mgstevens]

I was interested in this one as I had a similar issue, about a year ago, and in my case it was a somewhat corroded connector AND an iffy ground.

Thing was, I was installing LED work lights - nothing to do with the circuit or connections to the rear light assemblies - around that time and thought I'd messed something up, but no the corrosion and ground were waiting for "cover activity" to shut down...

In fact, most 12V problems I've encountered over the years had something to do with grounding issues. Grounding, corrosion (also the typical grounding problem) and wire damage from vibration are the most common culprits.

I used to lament how road vehicles stopped being easy to understand and diagnose, until I got an OBD2 dongle and a diagnostic program for my iPad. Still, I'm glad these machines are dead simple.

 

[Dmacleo]

Yup one broken wire inside connector to flasher unit. Tomorrow I'll try to unpin the contact push out and solder it but it's tiny and pretty rotted. May have to just flatten a wire solder end to create a contact point and super glue the wire to connector.

guess what just hit me again
the wire beside the repaired one.


massey of course does not sell the connector and their parts book now shows completely different style relay and connector.
I run this up and down main road a lot so want to fix them.
top left was first repair, the nasty one beside it is issue now. connector plastic is just rotting. may have to negate the connector and do wire by wire onto relay.

 

[Dmacleo]

considered buying new 8 pin relay and harness end and making my own, but the relay itself has no info on it as to what pin does what.
so I drilled (small bit) through the mess put some .032 aircraft safety wire (withstands vibrations well) with small hook on end (presses against the org contact harness side) thru and left little over 2 inches on harness side. little bit of superglue on harness end holds it in place.
tried to solder the safety wire to harness wire but safety wire would not hold solder. so small hook on that end and butt splice. then insulate.
works now.
tried to take picture but could not hold harness with one hand and zoom into wire and take pic with other hand.