Electrical Problem Affecting Headlights

2001 Tacoma DC Limited 4WD:

Here's the problem: low beam headlights not working. High beam working. High beam headlight indicator light on bright (blue light) on both low beams (which are not working) and high beams.

What done so far: Replaced headlight bulbs with new ones. Same problem. Replaced both (two) 10 A mini fuses. Lights started working as normally would. Problem appeared resolved.

Next Night: Same problem recurs. This time, however, smoke comes out of the area where the lever is to tilt the steering wheel.

Today: Problem appeared resolved.

Any idea what is the problem?

 

OK, here's the problem identified by the dealer service department:

The connector on the wiring harness, in which the headlight switch plugs into (under the dash), is damaged and beyond repair.

The solution is (1) a new wiring harness which costs about $1,200 and $1,800 labor for a total of $3,000, or (2) find a connector somewhere (junk yard, etc.) and it can be spliced into the current wiring harness and a new headlight switch ($75) installed.

Therefore, I need help finding a connector. The dealer looked in its bin of old wiring harnesses and tried to locate one but was unable to do so.

If someone out there has an old wiring harness for a 2001 Toyota Tacoma (not sure what other years would be compatible and maybe someone can advise if they know) with a usable connector for the headlight switch please let me know.

Thanks,

Robert

 

Here's a picture of the damaged connector.

 

I did some research on my own, and discovered the connector was available Toyota part number 90980-11672. Therefore, was able to fix by splicing the new connector into a new headlight switch. A lot less expensive than a new wiring harness. It turns out in this case that I knew more than the Toyota mechanic. The lesson is the dealer mechanics don't necessarily know the most efficient way to fix something.

 

Hi Robert, thank you for documenting your problem and solution for it. I'm having the same issue. Where did you purchase the replacement connector? Did it come with the terminals and some length of wire in place?
Thanks!

 

Michael, first welcome to TW

Second, you may not get a response from Rob. He hasn't been on in over 3 years. An easy way to check is to click on someone's user name and it will display the info.

You can try a "conversation" which is a PM/DM but that all depends if he gets updates.

You can do a Google search for that part number, this is the result:

https://www.google.com/search?ei=af.....0.76.476.7......0....1..gws-wiz.zVhG-DylzOw

You can also call a dealership or one of the listed parts places and see how much it would cost. GL

 

You could remove/cut the one wire in question out of both ends of the factory connector and add your own patch with a connector of your choice.

 

Thank you frizzman and Rob! I plan to purchase a new connector and terminal, and do as Rob mentioned.

 

I have the same problem...why dont these things come up when you type them in...this thread would of saved me 3 sets of bulbs and racking my brain for hours...