Purchased a Feb 1995 840ci 125,000 miles. Checked and found all fuses good. Rebuilt concealed headlight harnesses left and right, also rebuilt both harnesses turn signal running high beam left and right. All harness wires appeared badly undersized (too small diameter wire) as evidenced by browned insulation and cracking failed falling off wire insulation all harnesses. Does not appear to extend past cannon plugs (connections). With the headlights off the turn signals, emergency flashers, brake lights and flash to pass (lower set of high beams) work correctly. Turn headlights on and the upper low beams and fog lights (when selected) park and running lights work correctly. Fog lights on, pull flash to pass turns off fog lights, but no lower set of high beams on when pulled. When fog light on or off push for high beams turns off fog lights(if on), low beams stay on and no high beams upper or lower, blue high beam indicator light on instrument panel illuminates when push for high beams or pull for flash to pass. I have played a little dance with the relays which seems to solve one concealed headlight from getting out of synch with the other. Awaiting a relay in the mail. Any help appreciated. dcfrench1560@yahoo.com Thanks, Dave French
Your "lower" flash to pass will not work as High Beam lights as you are hoping, because you don't have a EURO coded LKM.
'93 850Ci - Mineralweiß Metallic
2001 740iL - Titansilber
ALPINA B7 -Alpinweiß III
...the price of cool ain't cheap!
For mine, the high beam relay was faulty. The new one fixed it right up!
Sounds like the high beam relay.
BTW, you're right about the harnesses. I decided to do something about it and have had upgrade replacements made.
They're ready to go as soon as I can put together an info sheet. All new components and fatter pipes throughout.
How come the middle half of any project always takes the most time?
Is there a better source than others for relays? I'm seeing the high beam relay on the Internet for between $150 and $180?
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Matthew M.
North Carolina, USA
1997 840Ci | 2001 740iL | 1985 308GTSi Quattrovalvole
How many you want? Have plenty of the 61 35 1 392 416 relays here. Contact me offline at: wuffer at shaw dot ca if interestedIs there a better source than others for relays? I'm seeing the high beam relay on the Internet for between $150 and $180?
91 850 (Panzer), 2012 Mini Cooper Countryman (WifeMobile) www.wuffer.ca
Thanks so much for the responses. I found two cracked solder joints on that relay and repaired them it's nice to have my high beams back. Wuffer, are you still selling upgraded lighting harnesses?
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Last edited by BobieM; 07-16-2017 at 09:34 AM.
Matthew M.
North Carolina, USA
1997 840Ci | 2001 740iL | 1985 308GTSi Quattrovalvole
Nope, never was selling them. You need Max Lumens for those. Contact him at: maxlumens at finemotoring dot com
91 850 (Panzer), 2012 Mini Cooper Countryman (WifeMobile) www.wuffer.ca
Check the seating of the pins in the canon-plug connector where these all meet. I found the ground pin had pushed out - pushed it in and voila!
Thank you, guys. I found the same problem today with the FTP relay, as the lights had become intermittent. She's in good shape now.
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Matthew M.
North Carolina, USA
1997 840Ci | 2001 740iL | 1985 308GTSi Quattrovalvole
I suspect the relay may also be my issue. Neither My high beams or flash to pass lights work but the indicator on the dash lights up when I use the stalk. I just picked up an E31 last week and I'm learning a lot and trying to fix all the little electrical quirks these seem to have compared to my E39s.
Read thru this thread and Determined that my Headlight relay is dead. Swapped it with another one in the box and high beams worked.
I am going to go thru and solder the circuit board as suggested by BobieM
How do you get the Case on the Relay open?
Small Screwdriver on both sides nice and warm from the Hair driver and pulled right out. Solder joints looked good, no cracks, no burn marks. Re Flowed all the joints and now my high beams work Thanks
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