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"G" Series

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  1. Before beginning procedure, see PRELIMINARY HORN SYSTEM CHECKS  under TROUBLESHOOTING.
  2. Depress horn switch. If horns operate, check for intermittent problem. If horns do not operate, go to next step.
  3. Remove horn relay from underhood fuse/relay center. Using test light connected to ground, test battery circuit of horn relay coil (Orange wire). If test light illuminates, go to next step. If test light does not illuminate, go to step  13.
  4. Connect test light between battery voltage circuit of horn relay coil (Orange wire) and horn relay control circuit (Black wire). Depress and hold horn switch. If test light illuminates, go to next step. If test light does not illuminate, go to step  14.
  5. Using test light connected to ground, test battery voltage circuit of horn relay switch (Orange wire). If test light illuminates, go to next step. If test light does not illuminate, go to step  15.
  6. Momentarily connect a 15-amp fused jumper wire between battery voltage circuit (Orange wire) of horn relay switch and horn control circuit (Dark Green wire). If horn does not operate, go to next step. If horn operates, go to step  11.
  7. Install horn relay. Disconnect horn harness connector. Connect test light to horn control circuit (Dark Green wire) and ground. Depress and hold horn switch. If test light illuminates, go to next step. If test light does not illuminate, go to step  16.
  8. Connect test light to horn control circuit (Dark Green wire) and ground. Depress and hold horn switch. If test light illuminates, go to next step. If test light does not illuminate, go to step  17.
  9. Inspect for poor connections at horn harness connector. If poor connection is found, repair as necessary. After repair, go to step  20. If poor connection is not found, go to next step.
  10. Connect 15-amp fused jumper wire between positive battery terminal and horn control circuit (Dark Green wire). Connect a second jumper between negative battery terminal and ground terminal of horn (Black wire). If horns do not operate, go to step  19. If horns operate, go to step  12.
  11. Inspect for poor connections at horn relay. If problem was found, repair as necessary. After repair, go to step  20. If problem was not found, go to step  18.
  12. Repair high resistance in horn control circuit (Dark Green wire) or horn ground circuit (Black wire). A resistance as low as 0.5 ohms could cause operating problems with horns. After repair, go to step  20.
  13. Repair open or high resistance in battery voltage circuit of horn relay coil (Orange wire). After repair, go to step  20.
  14. Repair open or short to voltage in horn relay control circuit (Black wire). Horn relay control circuit includes horn brush slip ring and horn switch. After repair, go to step  20.
  15. Repair open or high resistance in battery voltage circuit of horn relay switch (Orange wire). After repair, go to step  20.
  16. Repair open or high resistance in horn control circuit (Dark Green wire). After repair, go to step  20.
  17. Repair open or high resistance in horn ground circuit (Black wire). After repair, go to step  20.
  18. Replace horn relay. After repair, go to step  20.
  19. Replace horns. After repair, go to next step.
  20. Operate horn to verify repair. If horns do not operate correctly, repeat test beginning at step  2.
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