Section 2: Headlamp Switch Electrical Connector Replacement

CONTINENTAL (HARNESS KIT PART # F80Z-11654-AA)

1. Remove headlamp switch connector from the wire harness by cutting the wires 1/2 inch (13 mm) from the connector. Discard the old connector.

2. Refer to the table for wire color codes and splices to be used.

NOTE:
CIRCUIT B2 (195), WIRE HARNESS (WIRE COLOR: TAN W/WHITE STRIPE) WILL HAVE A DOUBLE CRIMP (20 + 20 GAUGE). THIS SHOULD BE SPLICED (BLUE SPLICE) WITH A SINGLE CRIMP (16 GAUGE; WIRE COLOR: TAN W/WHITE STRIPE).

3. Strip wires 0.5 inch (7.6 mm), then insert each wire into correct crimp barrel.

4. Using Crimp Tool (AD-1522), crimp all wires.

5. Heat splice with heat gun until tubing shrinks and adhesive flows from each end.

6. Temporarily connect new headlamp switch and install knob.

7. Connect battery negative cable.

8. Check operation of headlights, marker lights, tail lights and instrument panel lights.

9. Disconnect battery negative cable.

10. Remove headlamp knob and disconnect headlamp switch.

11. Fold wiring back in an "S" onto the harness and wrap with electrical tape to allow the extra wiring to be fitted into the instrument panel. See Figure 9.

12. Return to Step 10 on this attachment.

MARK VIII (HARNESS KIT PART # F8LZ-11654-BA)

1. Remove headlamp switch connector from the wire harness by cutting the wires 1/2 inch (13 mm) from the connector. Discard the old connector.

2. Refer to the table for wire color codes and splices to be used.

3. Strip wires 0.5 inch (7.6 mm), then insert each wire into correct crimp barrel.

4. Using Crimp Tool (AD-1522), crimp all wires.

5. Heat splice with heat gun until tubing shrinks and adhesive flows from each end.

6. Temporarily connect new headlamp switch and install knob.

7. Connect battery negative cable.

8. Check operation of headlights, marker lights, tail lights and instrument panel lights.

9. Disconnect battery negative cable.

10. Remove headlamp knob and disconnect headlamp switch.

11. Fold wiring back in an "S" onto the harness and wrap with electrical tape to allow the extra wiring to be fitted into the instrument panel. See Figure 10.

12. Return to Step 14 on this attachment.

TAURUS/SABLE (AUTO LAMP VEHICLES HARNESS KIT PART # F8DZ-11654-DA)

1. Remove headlamp switch connector from the wire harness by cutting the wires 1/2 inch (13 mm) from the connector. Discard the old connector.

11. Fold wiring back in an "S" onto the harness and wrap with electrical tape to allow the extra wiring to be fitted into the instrument panel. See Figure 11.

12. Return to Step 12 on this attachment for Sable vehicles or Step for Taurus vehicles.

TAURUS/SABLE (NON AUTO LAMP VEHICLES HARNESS KIT PART # F8DZ-11654-EA)

1. Remove headlamp switch connector from the wire harness by cutting the wires 1/2 inch (13 mm) from the connector. Discard the old connector.

2. The vehicle wire harness for non auto lamp vehicles may have auto lamp circuits. If this is the case, three (3) wires in the harness will have different colors as compared to the wires of the service kit connector assembly.Follow the table to splice the right wires.

3. Refer tot he table for wire color codes and splices to be used.

4. Strip wires 0.5 inch (7.6 mm), then insert each wire into correct crimp barrel.

5. Using Crimp Tool (AD-1522), crimp all wires.

6. Heat splice with heat gun until tubing shrinks and adhesive flows from each end.

7. Temporarily connect new headlamp switch and install knob.

8. Connect battery negative cable.

9. Check operation of headlights, marker lights, tail lights and instrument panel lights.

10. Disconnect battery negative cable.

11. Remove headlamp knob and disconnect headlamp switch.

12. Fold wiring back in an "S" onto the harness and wrap with electrical tape to allow the extra wiring to be fitted into the instrument panel. See Figure 12.

13. Return to Step 12 on this attachment for Sable vehicles or Step 11 for Taurus vehicles.