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Discussion Starter #1
Chasing down an intermittent headlight problem and found a dip beam lead cleanly severed ~3" inside a wrapped harness above the L wheel well. The break was clean across the insulation and conductors...some blackening of the copper at the break so it had been failing for a while. No damage to the harness wrap, the harness was secured and the break was not at a bend or obvious flex point. Adjacent wires look fine.

Baffled....manufacturing defect that took 30 years to completely fail?
 

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I read this quickly, but did this wire break actually impact the headlight, or was this a new head scratcher?
 

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Discussion Starter #5
It was an intermittent headlight outage that I compounded by replacing the fuse w one that was bad out of the box ( 3 of a bag of 5 had high resistance ). After checking all contacts, switches, etc. I finally started to work my way up the harness twisting and shaking it until I got a flicker.
 
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