From: Ronzo (rojoha@attbi.com)
Date: Mon Nov 18 2002 - 15:09:10 PST
If you let the smoke out of the wires, why does the electricity stop
flowing?
Dumb, dumb, dumb....
CUCV Horn Horrors
Symptoms: Push horn button, no noise.
1) observe no horn fuse in fuse block...AH HAH!!!
Install fuse in horn spot in fuse block...push horn button and....no
horn (now you wouldn't want to ask why there was no fuse in the horn slot,
now would you?)
2) Observe that with fuse in horn slot, and pushing on horn button,
there is a 'click, click' sound. Investigation reveals this is the horn
relay...remember location for further investigation.
3) Proceed to front of truck, observe horn is there (check). Notice that
there is a wire coming from horn...tug wire, get rewarded with a connector
not connected to anything. Hmmmmm.... Remove headlight bezel, look for
unattached connectors....no joy.
Crawl under truck, with big flashlight, observe a wire with a
matching but opposite connector to the one on the horn, carefully tucked
behind a wire harness. Untuck it. It magically reaches the horn connector,
but due to the grille and black out light and bridge plate, there is NO way
you can make the connection without disassembling the entire front end of
the truck.....hmmmmm.
4) To waste some time and avoid dis assembling truck for a couple of
minutes....get length of wire, strip both ends, stick one end in the horn
connector and touch other end to positive terminal of bottom battery. Jump
when horn sounds! DO NOT WONDER WHY SOMEONE WENT TO SO MUCH TROUBLE TO
TOTALLY DISCONNECT A PERFECTLY FINE HORN......
5) Find 2 pairs of really LONG nose pliers and finagle the connectors
together.
6) Go to cab, turn Ign Key....horn sounds like a wounded yak as soon as
key is turned....push horn button, horn gets louder! As added bonus glow
plug "WAIT" light goes out each time you push horn button, comes back on
when you release horn button. ???? Oh, what's this? Added bonus, smoke
coming from under dash!!!
7) Key off, unplug horn connectors, dive under dash and unplug 'HORN
RELAY' from harness. Horn relay does not feel hot???
8) Reconnect horn, turn key, horn resumes wounded yak imitation without
the relay in the socket. Horn does not respond to horn button anymore,
neither does the 'WAIT' light, but then again a plus in that there is no
more smoke.
9) Back to the manuals...Horn Relay connector has a 'RECTIFIER'(looks
like a diode or large resistor) stuck in the back of the connector....for
what purpose? Rectifier for M1010 is different from other CUCVs...why? What
does it do?
Anyone else come across something like this? There is not a lot of room
to strip off the binding tape off the harness before it goes to the fuse
box, ditto the horn relay harness. I haven't located the wiring diagrams in
the manuals yet, still looking. But a mite PO'd that some kind of screwy
wiring blunder involving a 3 wire connector for the horn can cause smoking
dash board and weird light show on dash lights. If the harness has melted
and shorted, well mega bummer. Maybe reason why truck got
surplussed....after all, rest of truck is cherry. And without coming up with
a working horn means no inspection sticker and no drivee truckee.
Maybe horn wire from horn button in column is shorting?
Anyone got some ideas on what's going on here?
Please???
Ronzo
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