1988 - 1998 (GMT400) Section for all discussion related to the 1987-1998 Chevrolet and GMC trucks.

1997 K2500 Headlight Wire Ripped

Old Oct 24, 2019 | 8:29 PM
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Manu's Avatar
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Default 1997 K2500 Headlight Wire Ripped

I have a 1997 K2500 (with the 454), and my headlights aren't working. After a bit of sleuthing I found my issue - a gray wire going into the multifunction switch is disconnected. I've verified that that's the problem because when I managed to get the 2 ends to touch the headlights went on.
Now normally I would just splice the wire, but the problem is, it's the very end of the wire, where it goes into a little plastic connector, and into the bottom of the switch.

View of ground zero from driver side, bottom cover of steering column is removed, right side of image is towards the steering wheel, left side is towards the kick plate

Closer view - gray burned wire is the offender

View from underneath, as you can see the green and brown wires are also losing insulation, and then the corroded bit under the brown is where the gray wire went

I can barely even get up there, and the end of the wire in the connector is just a few burnt strands. I've tried prying it off, as it seems it should come off, but it just doesn't.
It appears that my only solution will be to replace the entire switch (and it may be a good idea as some of the other wires seem to be on their way out as well), but I'd rather not, because, and this is a quote, "if someone wants to sell you a truck with a broken turn signal switch just keep looking for something with an easier repair like maybe a blown head gasket or something." And coincidentally, I've already replaced the head gasket on this thing, and so I am not interested in another 30 hours of work.
Is there some way of repairing this easier? I don't care if it's something janky like installing my own switch in a random location, and bypassing the multifunction switch altogether, I just need to get it fixed. Unless it would be easier to go the legit route and replace the whole thing? What do you guys think? Any ideas will be much appreciated.
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Old Oct 25, 2019 | 7:36 AM
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With other wires about ready to break off also, it would be better to just do it correctly now now instead of patching and having to go through it again multiple times. I would go to the junk yards and see what i can find.
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