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Pinpoint Test O: The High Beam Indicator Is Never On

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. O1 VERIFY HIGH BEAM OPERATION 
    • Verify the high beam headlamps operation.
    • Do the high beam headlamps operate correctly? 
    • Yes  : GO to O2.
    • No  : REFER to EXTERIOR LIGHTING to continue diagnosis of the high beam headlamps.
  2. O2 CHECK CIRCUIT 12 (LG/BK) FOR VOLTAGE 
    • Disconnect: Instrument Cluster C220a.
    • NOTE: Headlamps must be on for this test.
    • Place the multifunction switch in the high beam position.
    • Measure the voltage between the instrument cluster C220a-2, circuit 12 (LG/BK), harness side and ground.
      Fig 1: Checking Circuit 12 (LG/BK) For Voltage
      G03924747Courtesy of FORD MOTOR CO.
    • Is the voltage greater than 10 volts? 
    • Yes  : GO to O3.
    • No  : REPAIR the circuit. TEST the system for normal operation.
  3. O3 CHECK CIRCUIT 57 (BK) FOR AN OPEN 
    • Measure the resistance between the instrument cluster C220a-10, circuit 57 (BK), harness side and ground.
      Fig 2: Checking Circuit 57 (BK) For Open
      G03924748Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to O4.
    • No  : REPAIR the circuit. TEST the system for normal operation.
  4. O4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION 
    • Disconnect all the instrument cluster connectors.
    • Check for:
      • corrosion
      • pushed-out pins
    • Connect all the instrument cluster 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 instrument cluster. REFER to INSTRUMENT CLUSTER . TEST the system for normal operation.
    • No  : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.