TSB: T004/96

HEADLIGHT SWITCH REPLACEMENT PROCEDURES

APPLICABLE MODEL/VIN

1995 Protege

DESCRIPTION

Refer to the following procedures for headlight switch replacement.

NOTE: Service Managers should place a copy of these procedures in the 1995 Protege Workshop Manual (Section T).

PARTS INFORMATION

HEADLIGHT SWITCH REPLACEMENT PROCEDURES

WARNING: THIS PROCEDURE REQUIRES AIR BAG MODULE REMOVAL FOLLOW ALL SERVICE WARNINGS DESCRIBED IN SECTION T OF THE WORKSHOP MANUAL WHEN HANDLING AIR BAG MODULES.

1. Record all preset audio stations.

2. Remove the negative battery terminal.

3. Center the steering wheel and remove the following:

• Steering wheel

• Steering column cover

4. Attach tape to the clock spring to prevent movement. Refer to Fig. 1

CAUTION: Failure to apply tape to the clock spring will result in component damage.

5. Remove the three (3) screws and pinch the two (2) claws of the cancel cam together to remove the clock spring.

6. Remove two (2) screws holding the headlight switch to the combination switch body.

CAUTION: Hold the cover down with your fingers while removing the headlight switch screws. A ball bearing and spring are installed below the cover. These items must be reused.

Fig. 2

7. Remove the following:

• Cord cover

• Three (3) tie-wraps (1, 2, 3)

• Vinyl tape

• Sponge

Fig. 3

8. Remove the black, green and red wire from the 14 pin connector using the following procedures:

• Use a small screwdriver (or equivalent tool) to lift the locking bar at the top of the connector.

• Remove the terminals by lifting the tab with a suitable tool and sliding the terminal out.

CAUTION: Use care to avoid breaking locks while removing terminals.

Fig. 4

9. Mark the cord of the replacement headlight switch 135mm from the switch lever opening. Refer to Fig. 5.

10. Apply grease to the stem of the headlight switch lever. Refer to Fig. 5

NOTE: If additional grease is required, use that grease listed in the Parts Information section of this bulletin.

Fig. 5

11. Assemble the spring and ball bearing onto the replacement switch.

12. Assemble the headlight switch with spring and ball bearing onto the combination switch.

13. Verify that the switch movement is smooth.

14. Rewire the headlight switch harness as follows:

• Install a tie wrap at locations 2 and 3. (Location 1 was eliminated to increase flexibility).

• Attach the switch cord to the combination switch body where the cord was marked in Step 9.

15. Verify that the switch movement is smooth.

16. Insert the black, red and green wire terminals and depress the locking bar.

17. Apply new sponge where the other was removed.

18. Install combination switch

19. Install column covers, steering wheel and air bag module.

20. Connect battery.

21. Reset clock and audio stations.