Intermittent drop out of low and high beam head lamps.

[AQUAR]

Hi All,

Was driving along and suddenly the low beam dies and comes back on a bit later.
Only started to happen this week, but has been intermittent since then.

There is a 6 pin dual relay (2 X single pole single throw) plus a 4 pin single relay (1 X single pole single throw) that makes up the light circuits for park - low beam and high beam.The 6 pin controls the park lights and low beam plus power to the single relay (presumably high beam relay?). I pulled out both the relays and they seemed to test out ok on the bench.

But the problem is still there and when I tap the relay the low beam contact sometimes chatters.
So either the coil is partially burned out or there is a bad earth connection via the light swith.
I am hoping its the relay and would much appreciate any suggestions as to where I might get a hold of one.

The 6 pin relay is mirror wired and seems to be able to be reversed in the plug (?).
If so it might help pinpoint if its a relay coil problem or bad earth problem (ie stuffed switch).

The complete circuit is a bit of a mistery as it doesn't match that in my manual.
If anyone has a wiring diagram for a Sigma GJ SE sedan with electronic ignition that would help a lot.

[AQUAR]

It turns out to be the relay.
A small blob of solder fell out and the coil makes intermittent contact.

Been searching on the net but so far no luck.
Have send in a few requests to various wreckers as well.
If Madmagna has any at MITS - FIX - let me know.

Managed to pry the base plate off but the casing is stubbornly locked in place.

[magna buff]

1980-1983-- what do you need to know ?

yep its the relay stuffed
a low beam relay for a sigma hummm (F07W(F 10)) outdated
can you put up a picture ?
should be some other company (checking ) or a tridon substitute avail---- or needs to rewire -- a high/ low relay type ..not hard



under general relays --- if no luck contact tidon direct for the next best relay and the wire up how to




if you have a gregories what page are you on
colour code
rg red green
r red
rl red blue
rw red white
GL green blue
ok
42- high beam relay a 4 pin... Rg R R RL with two wires one going to 43
43- the lighting relay is a 6 wire -R RW RL R GW RL
44 - is a different type of 6 wire -B(earth)GW RW R R GL last wire ?

all R /GL go to head lights

[AQUAR]

@ Magna Buff,

Parked the Sigma GJ in the front yard and registered the magna TP so I have a car for driving.
And working on the verada KS to get it going again.

Verada job is turning out to be much bigger than I thought.
Going to start another thread on that, as I am scared to actually fire the car (after I get the fuel system fixed)!.

Back to the Sigma, I have decided it is easiest to just wire in two single pole single throw relays. As that will fix this issue for sure.
Got most of the electrical circuit worked out despite the confusing diagram in my repair manual (it doesn't actually show how the lamps are wired).
Also I did reverse the relay in its socket, so now I have low beam and high beam and dodgy rear lights.

[magna buff]

- yep re wire relay system --to something advancing- beyond the cave man

[AQUAR]

Did not realise you presented the above wiring diagram.
Its much better than what I've got in terms of the way the lamps are connected.
Just need to marry the above cct with mine for the complete "picture".

[magna buff]

you were so busy
.. no time to check your own topics huh

[AQUAR]

Yeah, too many balls up in the air!
Especially as I also help out on a video processing forum and a NAS box forum.

[AQUAR]

For any vistors interested in this "vintage" car repair topic (AKA keep the old bucket driveable).
Finally bought a pack of 5 relays from a Ebay vendor for $18.
They are SPST 4 wire 80 Amp relays, and came complete with pre-wired sockets, but without any mounting tabs.
There is no way that the wires to the relay contacts are rated for 80A (too skinny!) but still usable in this application (only a short bit of wire and not required to carry 80A!).
One nice thing is that the relay sockets can be slide connected together.

The Old Relay vs its Replacement.


I made a mounting bracket from some sheet metal to roughly duplicate the way the original relay was mounted.


This is how it all came together.

[magna buff]

nice job all round.
.

oh 80 amps maybe for fitting spot lights on the bumper