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Pinpoint Test A: The High Beams Are Inoperative

WARNING: This page is about a different car, the 2004 Mercury Monterey and 2004 Ford Freestar. However, it is still accessible from the selected car via links, so may be relevant.
  1. A1 USE THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCs) FROM THE SJB SELF-TEST 
    • Key in OFF position.
    • Using the recorded results from the SJB self-test:
    • Were any DTCs recorded? 

    Yes 

    If DTC B2586, GO to A2.

    If DTC B2598, GO to  A6.

    All others, refer to the SMART JUNCTION BOX (SJB) DIAGNOSTIC TROUBLE CODE (DTC) INDEX  for correct diagnostics .

    No 

    GO to  A11.

  2. A2 CHECK THE MULTIFUNCTION SWITCH 
    • Key in OFF position.
    • Disconnect: Multifunction Switch C202a.
    • Carry out the multifunction switch component test.
    • Refer to COMPONENT TESTING .
    • Is the multifunction switch OK? 

    Yes 

    GO to A3.

    No 

    INSTALL a new multifunction switch. Refer to STEERING COLUMN SWITCHES . CLEAR any DTCs. TEST the system for normal operation.

  3. A3 CHECK CIRCUITS 1394 (WH/RD), 1395 (RD/PK) AND 2068 (BK/LB) FOR SHORT TO POWER 
    • Disconnect: SJB C2280b.
    • Key in ON position.
    • Measure the voltage between multifunction switch C202a, harness side and ground as follows:
      CIRCUIT DESCRIPTION

      Connector-Pin Circuit
      C202a-6 1394 (WH/RD)
      C202a-1 1395 (RD/PK)
      C202a-3 2068 (BK/LB)
      Fig 1: Measuring Voltage Between Multifunction Switch C202a Harness Side And Ground
      G03245896Courtesy of FORD MOTOR CO.
    • Is any voltage present?

    Yes 

    REPAIR the circuit in question. CLEAR any DTCs. TEST the system for normal operation.

    No 

    GO to A4.

  4. A4 CHECK CIRCUITS 1394 (WH/RD), 1395 (RD/PK) AND 2068 (BK/LB) FOR AN OPEN 
    • Key in OFF position.
    • Measure the resistance between the multifunction switch connector, harness side and the SJB connector, harness side as follows:
      CIRCUIT DESCRIPTION

      Multifunction Switch Connector-Pin SJB Connector-Pin Circuit
      C202a-6 C2280b-40 1394 (WH/RD)
      C202a-1 C2280b-45 1395 (RD/PK)
      C202a-3 C2280b-4 2068 (BK/LB)
      Fig 2: Measuring Resistance Between Multifunction Switch Connector Harness Side And The SJB Connector, Harness Side
      G03245897Courtesy of FORD MOTOR CO.
    • Are the resistances less than 5 ohms? 

    Yes 

    GO to A5.

    No 

    REPAIR the circuit in question. CLEAR any DTCs. TEST the system for normal operation.

  5. A5 CHECK CIRCUITS 1394 (WH/RD), 1395 (RD/PK) AND 2068 (BK/LB) FOR A SHORT TO GROUND 
    • Measure the resistance between multifunction switch C202a, harness side and ground as follows:
      CIRCUIT DESCRIPTION

      Multifunction Switch Connector-Pin Circuit
      C202a-6 1394 (WH/RD)
      C202a-1 1395 (RD/PK)
      C202a-3 2068 (BK/LB)
      Fig 3: Measuring Resistance Between Multifunction Switch C202a Harness Side And Ground
      G03245898Courtesy of FORD MOTOR CO.
    • Are the resistances greater than 10,000 ohms? 

    Yes 

    GO to  A13.

    No 

    REPAIR the circuit in question. CLEAR any DTCs. TEST the system for normal operation.

  6. A6 CHECK THE HIGH BEAM RELAY (DTC B2598) 
    • Disconnect: High Beam Relay C1050.
    • Carry out the high beam relay component test.
    • Refer to COMPONENT TESTING for schematic and connector information .
    • Is the high beam relay OK? 

    Yes 

    GO to A7.

    No 

    INSTALL a new high beam relay. CLEAR any DTCs. TEST the system for normal operation.

  7. A7 CHECK FOR VOLTAGE TO THE HIGH BEAM RELAY 
    • Key in ON position.
    • Measure the voltage between high beam relay C1050-85, circuit 2037 (RD), harness side and ground.
      Fig 4: Measuring Voltage Between High Beam Relay C1050-85 Circuit 2037 (RD), Harness Side And Ground
      G03245899Courtesy of FORD MOTOR CO.
    • Is the voltage greater than 10 volts?

    Yes 

    GO to A8.

    No 

    REPAIR or INSTALL a new BEC. CLEAR any DTCs. TEST the system for normal operation.

  8. A8 CHECK FOR SHORT TO POWER ON THE HIGH BEAM RELAY COIL GROUND CIRCUIT 
    • Measure the voltage between high beam relay C1050-86, circuit 1708 (LG/BK), harness side and ground.
      Fig 5: Measuring Voltage Between High Beam Relay C1050-86, Circuit 1708 (LG/BK), Harness Side And Ground
      G03245900Courtesy of FORD MOTOR CO.
    • Is the voltage greater than 5 volts? 

    Yes 

    GO to A9.

    No 

    GO to  A10.

  9. A9 CHECK THE SJB FOR A SHORT TO POWER 
    • Key in OFF position.
    • Disconnect: SJB C2280b.
    • Key in ON position.
    • Measure the voltage between high beam relay C1050-86, circuit No 1708 (LG/BK), harness side and ground.
      Fig 6: Measuring Voltage Between High Beam Relay C1050-86, Circuit No 1708 (LG/BK), Harness Side And Ground
      G03245901Courtesy of FORD MOTOR CO.
    • Is any voltage present? 

    Yes 

    GO to A10.

    No 

    GO to  A13.

  10. A10 CHECK CIRCUIT 1708 (LG/BK) FOR SHORT TO POWER 
    • Key in OFF position.
    • Disconnect: BEC C1035a.
    • Key in ON position.
    • Measure the voltage between high beam relay C1050-86, circuit 1708 (LG/BK), harness side and ground.
      Fig 7: Measuring Voltage Between High Beam Relay C1050-86, Circuit 1708 (LG/BK), Harness Side And Ground
      G03245902Courtesy of FORD MOTOR CO.
    • Is any voltage present? 

    Yes 

    REPAIR or INSTALL a new BEC. CLEAR any DTCs. TEST the system for normal operation.

    No 

    REPAIR the circuit. CLEAR any DTCs. TEST the system for normal operation.

  11. A11 CHECK THE HIGH BEAM RELAY (NO DTCs) 
    • Carry out the high beam relay component test.
    • Refer to COMPONENT TESTING for schematic and connector information .
    • Is the high beam relay OK? 

    Yes 

    GO to A12.

    No 

    INSTALL a new high beam relay. CLEAR any DTCs. TEST the system for normal operation.

  12. A12 CHECK THE HIGH BEAM RELAY OPERATION 
    • Connect a fused (15A) jumper wire between high beam relay C1050-30, circuit 2037 (RD), harness side and high beam relay C1050-87, circuit 1337 (VT/YE) (LH headlamp) or 1335 (YE/WH) (RH headlamp), harness side.
      Fig 8: Checking The High Beam Relay Operation
      G03245903Courtesy of FORD MOTOR CO.
    • Do the high beams illuminate? 

    Yes 

    GO to A13

    No 

    REPAIR or INSTALL a new BEC. CLEAR any DTCs. TEST the system for normal operation.

  13. A13 CHECK FOR SJB OPERATION 
    • Key in OFF position.
    • Disconnect all SJB connectors.
    • Check for:
      • Corrosion
      • pushed-out pins
    • Connect all SJB connectors and make sure they seat correctly.
    • Operate the system and verify the concern is still present.
    • Is the concern still present?

    Yes 

    INSTALL a new SJB. REFER to SMART JUNCTION BOX (SJB) . TEST the system for normal operation.

    No 

    The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR any DTCs. REPEAT the self-test.

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