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No Brake Lights, Turn Signals, Tach, Fuel Gauge

1903 Views 24 Replies 11 Participants Last post by  awlb
Hello friends.

1994 NAS D90 Soft Top, 105k miles.

Everything working perfect until I take it to the garage for the PA state safety inspection! Literally drove to their lot, made sure brakes and signals etc worked and expected a fast and easy inspection since I only put 200 miles on in the last 12 months. But alas, not to be!

Whats not working:
  • Brake lights
  • Turn signals
  • Tach not functioning
  • Fuel gauge not functioning
  • Front Wipers and squirters not functioning
  • No reverse light

What is working:
  • Every other electric!
  • Headlights
  • Horn
  • Parking lights (fore and aft)
  • Starts and runs, drives fine.

Here is what I've done:
Got it to pass inspection when I wiggled the turn signal relay. Seemed to come right back on and everything worked. So, I replaced the relay with a new one from AB and everything continued to work for about 60 seconds. Now Im back to all the above being dead again. Again everything just was functioning as it should have and now, nothing.

  • I checked every single fuse in front of the gear shift in the interior. Pulled each one, visual inspection and all were good.
  • Checked for loose wires, corrosion at the tail lamps. I recently replaced the bulb carriers so Im 99% certain those are in good condition
  • Ran a continuity test from the bulb carriers and had audio confirmation the circuits were good (brakes applied, signal stalk on etc...)
  • Pulled steering wheel off, disassembled the column to check for loose wires - nothing (I had replaced a couple years ago the turn signal stock with new)
  • Double checked the newer relays in the passenger (RH) footwell as sometimes my kids kick up there unknowingly and knock something loose.
At a loss and appreciate specific guidance. I should admit I did search here for this issue and found many entries of the same/similar but their fixes did not resolve my issue.

Im certain many of you will say, "check your grounds" but if you can be specific as where exactly I should be looking that would be appreciated! Thank you in advance!!!


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I added a new heavy duty ground from the engine block, passenger side to the inside of the wing. I did confirm all the other grounds were solid. Even after this, the wire continued to smoke upon attempting a start. I traded out relays but at that point it was too late as that ground had smoked through the plastic.

But I do agree, why would that have happened in the first place? Bad main ground somewhere, or open relay redirecting current when it shouldn't have?

And, to note, the instant I turned the key to start the truck, the smoke appeared. Check out the you tube video I had posted above. (HERE )
Sounds like you got a"-"where a"+" should be...or the other way around.
Sounds like you got a"-"where a"+" should be...or the other way around.
Strange though, I made no changes to anything prior to this happening. It was in storage for 6 months with the occasional start and run and on a battery tender.
I feel your pain, after my 110 sat in 4 feet of water for 10 days - I had a myriad of electrical issues. Intermittent, seemingly random, always aggravating. Not until I removed nearly ALL the PO's hack job, 2 miles of wires, crimped all connections (no solder), cleaned every ground I could find, redid the fuse box, AND start drinking - did it finally resolve to the point where I could drive at peace knowing everything fires up when it is supposed to. I even have "accessories".

I'd trace every wire I could, replace any damage with the appropriate gauge wire, make sure all your grounds are solid. Rinse a repeat until you have been through everything.

At the worst you will learn alot. Good luck!!!
Strange though, I made no changes to anything prior to this happening. It was in storage for 6 months with the occasional start and run and on a battery tender.
Doesn't mean it was correct to start with. Electrolysis grows constantly. The "heavy"(main) wiring on defenders is very simple to inspect/clean/replace. Start @ the battery(s) and work your way out. Good luck!
Oh yes - really important point I forgot to mention! There is NO hazard switch! Some PO must have removed it ? No idea about it other than the 8-10 years I have owned this, never an issue but again, no hazard switch anywhere to be found.
My truck had no hazard switch (so I thought) until I pulled the dash and there is was, still connected but hiding behind the gauge cluster. The handiwork of prior owners is often a challenge!
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